2002 x5 transfer case/front drive shaft problem

[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.