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.

[racemalibu572]

Originally Posted by dville

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.

I see that now, due to living in the middle of the "rust belt", it appeared that the pilot flange and the shaft were one piece. Working on it at 3am didn't help either, I just wanted to get it apart. The first prototype I put in my own car was a little longer than the new production pieces, so I had to remove the case. As ttzcar just posted, the new extended shaft goes in with out having to completely remove the case. I would like to give a big thanks to Joe and Jimmy for being so patient during getting these made, we ran into a few bumps but it looks like smooth sailing ahead. I have some pictures to upload of the new shafts, I'll get them up shortly.

[racemalibu572]

Here are some pictures of the new shaft repair components.
These are the new one piece blanks I had made.


This will give you a good idea of what the damaged shaft looks like and the amount of good spline that gets used.


The press fit step is machined to fit the i.d. of each shaft repaired. Runout is checked as it's being machined as well as when it is being welded in.


Here is the first finished shaft.


I haven't ordered any more blanks yet to keep in stock, but if you need one done they're only 4 days for me to get, so I can have them by the time I receive your core. If I get enough interest in these I plan on having some finished shafts in stock. If your interested in having one done please call me at 262-749-0689 or e-mail me at [email protected]. Thanks again, Tom Gottschalk.