2002 x5 transfer case/front drive shaft problem

[racemalibu572]

Originally Posted by 01 BMW_X5

75%??

Ok, it wasn't that bad, but just not used to pulling the exhaust, a couple of large heat shields, rear drive shaft, transfer case crossmember and then split the trans and case to get a front drive shaft out. Without any u-joints you can't tilt it down far enough to get it out.

[BAX5]

Not having seen this area, but sounds like they should have put in a grease nipple or boot.

[ttzcar]

DAMN!!! My X5's "transfer case" just took a crap last night.
When I put it into drive or reverse it makes the LOUDEST grinding noise ever.
I got underneath the car and the noise is definately coming from the transfer case. I pray it's not the transmissiom, but I have no codes or lights saying my transmission is out.

My question:
The transfer case seems easy to get to, but I've noticed some people are taking their cars to a shop. Is that because of the balance of moving parts in that area? Or just don't want to deal with it? On this car I've replaced my radiator and water pump myself and honestly this transfer case seem alot easier. However I'm not mechanic what so ever, I can just take things apart and put them back together (I think). A buddy of mine was saying that the bolt should be marked and put back in in the exact same order to keep the balance the same and all kinds of BS which was scaring me.

Any help?
Also... It's not my tranny right? *crossing fingers*

Thanks,

[Werewolf]

Originally Posted by x5pete

I had mine fixed. Originally, I had taken it to the dealer and he said it needed a new transfercase and a front drive shaft. He quoted me $4300 plus tax. This seemed like a little too much to put into an '01 car with 103k miles so I had it towed to an AAMCO that a family member had used for a repair. I ordered the transfer case myself from transfercases.com (for $895)and I found a used front drive shaft with 65k miles in great condition (for $300). The whole repair was done with parts and labor (about $500) for under 2k and now the car is working great again.

x5pete, where did you get the used front drive shaft?

Also, what sort of mileage did the vehicle have before failure and what were the signs of the failure?

Thanks

[x5pete]

I had just over 100k miles. The vehicle is a 2001 x5 3.0 that I 've owned for almost 8 years.

There were no warning signs. I was at a stop light. I attempted to go and a grinding sound came from under the car. The car would not move. I had it towed to the dealer who gave me the estimate indicating that it was the transfer case and the front drive shaft that needed to be replaced. He wanted to get only new parts, 2500 for the transfer case and 900 for the front drive shaft and then labor totaling 4300. For a car with 100k miles, I said no way and I towed it to a local shop (non-BMW) who dealt with transmissions and he said it wouldn't be hard to fix. I got the transfercase on line a transfercases.com I believe for about 1k and then the shop called some junk yards and found a good condition front drive shaft from a junked x5 for $300. Actually, I googled the part and there are cheaper ones available on line (about $250 or so).

I would have done the repair myself and I'm not a mechanic but I don't have access to a lift so I though it would be a little too challenging so for $400, the mechanic did the labor in a morning. I now have about 104k on it and no problems. I am in NY and the junk yards seem to be around NY where they found the used front drive shaft but I don't know which yard. Also, I tried to locate an aftermarket part and nobody seems to make a replacement front drive shaft.

[racemalibu572]

You most likely have stripped splines where the drivehaft goes into the case. I fixed mine with a custom made shaft that has a 1" longer spline. Bmw only uses about 1/3 of the spline in the case, about a 5/8"-3/4". The seal goes bad and the splines start to rust and eventually wear down till they strip. I am going to be making replacement shafts on an exchange basis for around the same price as a new aftermarket shaft (that wont help unless you buy a reman. case) You will have to remove the case for a minute to install the new shaft because of the longer splines, but it will save you around $1000 for a reman. case and used stuff will probly do it again in the future. I did mine on a lift so it was pretty easy, you should be able to do it on some good tall jack stands. If you can change a water punp, you can do this, just have a helper when you slide the case back to install the shaft. My setup uses a good inch+ of clean spline and the 1/2 splines that are still left, way more than bmw used. I'm still waiting for my blanks to make another shaft, I've been testing the prototype (beating the crap out of the x5) for a few thousand miles with no problems. If your interested, you can call for more info 262-749-0689 8am-6pm cst.

[racemalibu572]

A couple of pictures.
the prototype is two parts tig welded together, the new parts will be one piece and have the lip for the factory seal. I made a seal that I had laying around work because of time.

[ttzcar]

So I towed my car to Aamco because they offered free inspection and they quoted me $4,100 to fix. Transfer Case and Front Drive-Shaft. I'm going to tell them NO and tow my car out tomorrow and attempt ordering one from Ebay or TransferCases.com And I'll have t find a used Front Drive Shaft somewhere.

[dville]

Originally Posted by racemalibu572

Ok, it wasn't that bad, but just not used to pulling the exhaust, a couple of large heat shields, rear drive shaft, transfer case crossmember and then split the trans and case to get a front drive shaft out. Without any u-joints you can't tilt it down far enough to get it out.

You do NOT have to take of transfer case to remove front driveshaft.
I just did it (I have BMW TIS CD).
The reason the splines on the transfer case have so much extra room is so you can remove the front driveshaft.
You simply remove the front stiffener plate, undo the bolts at the front driveshaft flexdisk, then use a crowbar and slide the shaft backwards until the flexdisc can slide out (it has a centering device that sticks into the flange on the front differential preventing it from just dropping out).

If you lengthen the front driveshaft, then you will HAVE to remove the transfer case to take out the front driveshaft, since you will not be able to slide the shaft backwards to clear the flexdisk.

[dville]

FYI: Cobra Transmission Parts 1-800-293-1848: BMW X5 Transfer Case Chain