Transfer case

[nikpottala]

No need to replace the entire TC, just get the replacement gear, a new chain, and driveshaft from cobra transmission and be done with it. If you can remove the transfer case from the car you should be able to change the TC gear/chain and it will save you about $2000 or more when compared to the cost of the TC. Even if you have to pay someone to remove it and put the replacement parts in, you be money ahead vs. buying a replacement TC.

My quick repair didn't last a year so just do it right. IF you have the replacement parts, it can be done in a weekend (likely one day depending on your skills). It took me less than 1.5 hours to have the transfer case on the floor.

[Turbo_Bimmer]

Most AWD BMWs seem to share the same arrangement as far as front driveshaft/diff/TC are concerned. That means they also share the same problems.

Concerning the driveshaft splines stripping in the TC hub, like it has been said, the fact that the spines don't engage very far into the TC doesn't help since the load is spread only on a small part of the splines.

That problem is also present on the E30 325ix.
I did something to my ix that I think could be applied to the X5 to help the driveshaft spines live longer, or give few extra miles to a damaged one (assuming the the TC hub is still good).

I fabricated a 1/2" spacer to fit between the front diff flange and the driveshaft. With that spacer installed, almost all of the driveshaft splines are inserted inside the TC hub.
The holes in the driveshaft need to be threaded, and studs made. That solution seems to work well. My E30 is turbocharged, and the splines are still thight.

Here are a couple of pictures:

[ayagutak]

Ok if replace no driveshaft with a new shaft not a extend one, just a new one OEM driveshaft, should it work ok or do I need the 1inch extension on the shaft to make it work,

[nikpottala]

Don't need extended if you replace the tansfercase gear however the extended shaft may wear a bit longer. My original stock setup ran 150,000 miles.

[ayagutak]

hi ... OK i got the new drive shaft 1 inch spd, my question is what most I do when putting it in, and should i lube the spindly, I have read that the transfer case most be push back for the new 1 inch spindly,should it be drop also... please write the procedure in putting spindly. I'm have it done this week ( help)

[nikpottala]

Yes, make sure you lube the spline liberally. You won't have to drop the transfer case entirely to insert the driveshaft. I removed all but a few bolts. The bolts I left in I unscrewed to the point where they might have 2-3 threads inserted, then slide your transfer case back and the drivehshaft should fit with a bit of wiggling.

[ayagutak]

ok thk will report back when its in.....

[ayagutak]

OK the driveshaft is in, it took a mechanic about 10 hours to get it in, only cost me 300$ plus 750 for the driveshaft with the extra 1inch,,,,the x5 sound different with me new driveshaft, kinda rough,when in drive in D, but sounds OK in R,wondering if that the way it should sound with the extra inch....

[ayagutak]

the roughness is gone, the transfer case wasn't torch enough, all is good i'm very happy to be back on the road the extra 1inch on the drive-shaft works,
thanks to all