Transfer case removal pictures...

[semcoinc]

I just finished reading all 16 pages of this thread. Nothing short of outstanding contributions.

BIG props to the OP for getting this thread rolling 7 years ago!

I'm not experiencing any of the chain slop symptoms on my 96K mile 4.4i but will have this great guide if I need it.

Thanks again folks.

Mike

[DSSA]

Originally Posted by x5glenn

I just got done doing ths repair and did it your way leaving it on the car. It was surprisingly easy. I only removed the support frame, disconnected the driveshaft and bungee corded it to the exhaust to get it out of the way and then opened up the case and replaced the chain by sliding out the gears. The only thing I would add is that the gear with the snap ring has a dust shield on the outside that needs to be pried back so the gear pops right out when the snap ring is expanded. Leaving the transfer case on the car I was able to complete this DIY in about 4 hours going slowly and learning as I went.

I purchased my X5 with bad driveshaft/transfer case splines, so this was the first thing I ever did to it.

You are correct, it's not that bad of a job, if you have a lift, trans jack and air tools. I had the transfer case on the ground in about 45 minutes.

The chain and seals are pretty cheap to get (remember, this is a NV transfer case, not something BMW cooked up), but I ended up having two issues:

1) I couldn't find a replacement front output shaft (front shaft that has the splines for the driveshaft that goes to the front differential), and I didn't trust just doing the driveshaft spline extension. I had it torn down, new chain and seals, but just didn't like the looks of that front output shaft, so I bought another transfer case to start with, and also did the spline extension on the driveshaft.

2) Noting again that this is an NV transfer case, I'm not sure why they suggest using ATF in them, other than to cut down on noise when they're cold. Every other NV transfer case I've ever seen uses gear fluid, and the places I see rebuilding these units insist on use of gear fluid, or they will not honor the warranty. I'm thinking this is partially why these chains stretch so much more commonly than other NV units (or else BMW just under-spec'd these units when they incorporated them).

Disclaimer to above: All information is concerning the non-X-Drive units. I have not worked on the X-Drive ones.

[Werewolf]

Dville,

What problems / symptoms were you having before you made this repair?

[chadtoolio]

Update.....

I you don't remove the tranfer case to do the repair like I did, make sure you don't flip the lip of the seal for the output shaft seal for the front diff.

Werewolf,

Not Dville, but I have one that was doing the same thing and under heavy accelleration and loads, there is a loud popping underneath the vehicle that can be felt through the driveline. Pop-pa, Pop, Pop, Pop. You'll thing something is getting ready to come apart hardcore. It's just a nasty sounding noise. If I let the trans kick down at under 30mph I could get it to do it as well, but definitely from a standing start and lunge forward(or attempt to), you'll hear it.

[jhandy393]

fantastic write-up! almost inspired me to attempt this job, myself...almost.

my x5 (2001 4.4, 190k mi) has the same symptoms as described here. i have been talking with an indy tech about changing out the chain, instead of replacing the entire transfer case. he says he'll do it, but if he gets inside the case and there's more damage (bearings, gears, or damage to the case itself caused by the loose chain), he'll still have to replace the case...and charge me for the internal inspection and the Xfer case replacement. so i have decision to make, and am asking for advice. should i risk it, and let him open up the case in the hopes that we can get away with just changing the chain? is there frequently more internal damage when the chain wears out? or should i just bite this bullet, buy a case and have him install it? what are your opinions? upon successful repair, i plan to keep this vehicle at least a couple more years.

[dville]

Originally Posted by jhandy393

fantastic write-up! almost inspired me to attempt this job, myself...almost.

my x5 (2001 4.4, 190k mi) has the same symptoms as described here. i have been talking with an indy tech about changing out the chain, instead of replacing the entire transfer case. he says he'll do it, but if he gets inside the case and there's more damage (bearings, gears, or damage to the case itself caused by the loose chain), he'll still have to replace the case...and charge me for the internal inspection and the Xfer case replacement. so i have decision to make, and am asking for advice. should i risk it, and let him open up the case in the hopes that we can get away with just changing the chain? is there frequently more internal damage when the chain wears out? or should i just bite this bullet, buy a case and have him install it? what are your opinions? upon successful repair, i plan to keep this vehicle at least a couple more years.

Print out this thread and take it to him. If he is hard headed, leave it on the passenger seat in a really obvious place (he'll use it).
Tell him to just change the chain.
And from the post above, you don't have to remove the transfer case either saving you some $$.

Don't see why your case should be any worse than the others on here.

[stef]

Excellent thread, thx for sharing it.

[beewhy]

dville the write up and pics are wonderful but as I sit here the 1st of jan 2011 8:00 with a x5 half way torn down i notice that you and others left the write up and pics on how to remove both drive shafts and what wrench/tool needed. I have searched the site and it seems this is vital info need to complete the job....

[dville]

Originally Posted by beewhy

dville the write up and pics are wonderful but as I sit here the 1st of jan 2011 8:00 with a x5 half way torn down i notice that you and others left the write up and pics on how to remove both drive shafts and what wrench/tool needed. I have searched the site and it seems this is vital info need to complete the job....

front driveshaft: take of metal plate under engine, remove bolts holding driveshaft to diff. slide forwards.

Rear (from memory): center bearing has to be lowered, then remove hex bolts at rear diff. slide backwards

[beewhy]

Thanks dville , I have a 3.0 and noticed some slight differences between the two. I would like to thank you for your write up it saved me $2500 and thanks to racemalibu for actually taking the time to advise me to fix the transfer case first and for directing me to dville's post!! Your a stand up guy and I will try to send you business!