Transfer case actuator gear failed again

[pghguy517]

About 2 months ago I got the 3 lights (ABS, DSC, and 4X4) and clicking noise when shut down. It was a stripped plastic actuator gear like many others posted here. I replaced the gear with an Odometer Gears brand, and its been working great until last night. Same 3 lights and clicking sound. I'm sure its the gear again. What would cause this to happen? First gear went out at 96,000 miles, now at 100,000. All looked good inside the actuator (except for the stripped plastic gear), no sharp teeth on the metal worm gear, no excess slop in the gear and shaft. cleaned out the old grease and broken plastic gear parts, used the recommended marine wheel bearing grease. What gives? Thanks for any help on this.

[Gregory891]

You don't mention what year & version of X5 you have, which makes a difference as there are different types of transfer cases on these cars. I am guessing you have an E53. It sounds like you have a car with the later ATC500 transfer case (they type with the electric actuator). The actuators are known as an item that is frequently replaced.

I have the earlier NV125 transfer case (pre-iDrive). I can recommend Automatic, Standard Transmission and Transfer Case Rebuild Kits, Cobra Transmission Parts 1-800-293-1848, Cobra Transmission if you need parts, THE only place to find magnetic drain plugs (which BMW didn't install at the factory) for long life.

[pghguy517]

Sorry, it's a 2005 4.4. Thanks!

[Gregory891]

In this case my guess was accurate, you have the ATC500 transfer case.

Check with the guy at Odometer gears, I've counciled him on a BMW E12 project and helped him find some race parts he needed. He's knowledgeable about the ATC500 gear issue.

[pghguy517]

Will do, thank you,

[rb0135]

Did you recalibrate it with the new gear using GT1/DIS?

People say you don't have to and say they have never had issues but I follow the TIS manual and if BMW say to calibrate after any kind of service on it, I do.

It could have been a faulty part to start with.

By what you state, you did follow the correct instructions of changing it.

You don't say whether you have opened it up to see whats happened with this gear.

[bigwave2255]

what about if you just flip the gear, as has been discussed before, do you think you still need to do a reset??

and how involved is it to do, its an area of my car i haven ventured into,

i havent had any issues with my actuator as yet, although i have over 180,000 km on the car, im wondering if a lot of the problems are not due to the nature of the driving.

i commute 100km per day ,all freeway driving and im wondering as i dont see lots of

wheel slip situations maybe thats why i haven't had issues.

also due to peak hour type driving my car rarely see loads of torque applied

im more likely to wear out brakes before anything else.

[Bimmer_Me_Up]

I had the same three lights turn on this weekend. There is also a brief clicking noise under the car when turning off the engine. I found a video on Youtube showing this exact scenario and a DIY to replace the Transfer Case Actuator Gear. https://www.youtube.com/watch?v=3xEJbpVupuw

One guy posted that it may be as simple as the speed sensor and it might be as bad as ABS module, and that you should have it diagnosed first.

Based on the symptoms, I think I will check the gear and if it is that, I will replace the transfer case oil as well. Has anyone else had this issue?

[e30cabrio]

Originally Posted by Gregory891

In this case my guess was accurate, you have the ATC500 transfer case.

Check with the guy at Odometer gears, I've counciled him on a BMW E12 project and helped him find some race parts he needed. He's knowledgeable about the ATC500 gear issue.

Which type does an 03 4.4 have?