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  #1  
Old 05-22-2014, 07:34 PM
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Exclamation Transfer case actuator motor gear.

Hey I've been noticing that at around the right RPM's my 4x4 ABS light and brake light come on (deactivating all 3). Also when i turn off the engine i hear a clicking noise from under the car. So i did some research, and its become apparent to me that the transfer case actuator gear is worn out. Im usually someone to repair things on my e53 myself (DIY), so i order the gear the seems to be the actual problem so i can replace it this Saturday. While I'm waiting I'm wondering if anyone can tell me how do i take it out from under the car, Or is their a write up or video where someone is detailed about how they take it out from under the car. A lot of videos I've seen they skip that whole part.
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  #2  
Old 05-22-2014, 08:59 PM
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Go to youtube and look up briansmobile1 he has a video on removing the actuator. There's also a video on replacing the gear on youtube just do a search.
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  #3  
Old 05-22-2014, 11:37 PM
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Quote:
Originally Posted by upallnight View Post
Go to youtube and look up briansmobile1 he has a video on removing the actuator. There's also a video on replacing the gear on youtube just do a search.
Thanks.
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  #4  
Old 06-09-2014, 11:44 PM
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I just did the gear replacement and since there is so much information spread out around the internet and in forums on this topic I created a post to try to consolidate it (see below). So far so good, it fixed the problem no more warning lights and no more clicking when I turn off the car. I chose to replace the gear with a new one rather than risk it failing or slipping back into the worn out portion of the gear, my reasoning being if I was going to spend a Sunday working on this I didn't want to ever have to repeat it

I included my photos and the 3 best videos I found on the problem/replacement:

BMW Transfer Case Actuator Problem And Fix

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Old 06-10-2014, 08:15 AM
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Quote:
Originally Posted by jv2000 View Post
I just did the gear replacement and since there is so much information spread out around the internet and in forums on this topic I created a post to try to consolidate it (see below). So far so good, it fixed the problem no more warning lights and no more clicking when I turn off the car. I chose to replace the gear with a new one rather than risk it failing or slipping back into the worn out portion of the gear, my reasoning being if I was going to spend a Sunday working on this I didn't want to ever have to repeat it

I included my photos and the 3 best videos I found on the problem/replacement:

BMW Transfer Case Actuator Problem And Fix

This article is an attempt to aggregate information in a single place regarding a defect in the X drive systems of BMWs that will typically affect ALL of the following models of BMWs at one point or another, typically around 80k-120k miles.

2001-2003 BMW X5 3.0 L6 E53
2004-2006 BMW X5 E53
2004-2010 BMW X3 E83

The model year 2001-2003 BMW does not have an actuator gear in the transfer case. See Realoem.com. It uses a different transfer case.
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2006 Infiniti G35
2001 BMW 3.0I E53 X5 Build date 08/2000 SOLD
Lotus Europa 1970 Destroyed by fire
Lotus Europa 1970 S2 Renault Powered
Lotus Type 52 1970 Twincam Webers Powered
PORSCHE 911 Targa 1982 The Garage Queen
Audi Avant donated to Kars for Kids
BMW 525IT Sold
Audi 4000CS Quattro Sold
Jensen Healey Lotus Powered Sold
Opel 1900 Sold
Triumph Spitfire 1971 Sold
Triumph Spitfire 1968 Sold
Plymouth "Cuda" 340 Six pack SOLD
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  #6  
Old 06-10-2014, 11:09 AM
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Thanks for catching that, updated. I was basing that off of a part spec that I saw but that must've been in error ...

Quote:
Originally Posted by upallnight View Post
This article is an attempt to aggregate information in a single place regarding a defect in the X drive systems of BMWs that will typically affect ALL of the following models of BMWs at one point or another, typically around 80k-120k miles.

2001-2003 BMW X5 3.0 L6 E53
2004-2006 BMW X5 E53
2004-2010 BMW X3 E83

The model year 2001-2003 BMW does not have an actuator gear in the transfer case. See Realoem.com. It uses a different transfer case.
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  #7  
Old 06-10-2014, 11:20 AM
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Just as an FYI. Over 2 years since I have flipped my gear. I have all 4 seasons here, and drive it like I stole it from time to time.

http://www.xoutpost.com/bmw-sav-foru...ixed-sort.html

It is important to mark the position of the gear on the outside, before you take the motor out.
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Old 06-10-2014, 01:11 PM
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Hi SlickGt1,

Do you replaced just the "gear" with an updated part or you elected to replace the actuator (pn# 27107566296)?



Quote:
Originally Posted by SlickGT1 View Post
Just as an FYI. Over 2 years since I have flipped my gear. I have all 4 seasons here, and drive it like I stole it from time to time.

http://www.xoutpost.com/bmw-sav-foru...ixed-sort.html

It is important to mark the position of the gear on the outside, before you take the motor out.
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Build Date: 06/2004

2004 E53 3.0L 6 Cyl
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2004 E46 M3 Coupe 3.2L 6 Cyl
Engine Code: S54
MT: S6S 420G - 6 speed
http://s101.photobucket.com/user/lho...in/library/E46
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Build Date: 10/2008
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  #9  
Old 06-10-2014, 02:26 PM
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Quote:
Originally Posted by lhordmclain View Post
Hi SlickGt1,

Do you replaced just the "gear" with an updated part or you elected to replace the actuator (pn# 27107566296)?
I just flipped the gear 180 degrees. Took me all of 15 min to do, oh and free.
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  #10  
Old 06-10-2014, 02:37 PM
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Edit: Given 2 years since you did the alternative "free" solution

How many miles after that?

At least you can tell the story whether "flipping the gear 180 degrees" was short term fix or can even last longer ( wild a** guess equal or greater than 30,000miles)


Quote:
Originally Posted by SlickGT1 View Post
I just flipped the gear 180 degrees. Took me all of 15 min to do, oh and free.
__________________
Build Date: 06/2004

2004 E53 3.0L 6 Cyl
Engine Code: M54
AT: 5L40-E/GM5 (A5S 390R)
http://s101.photobucket.com/user/lho...in/library/E53

2004 E46 M3 Coupe 3.2L 6 Cyl
Engine Code: S54
MT: S6S 420G - 6 speed
http://s101.photobucket.com/user/lho...in/library/E46
----------------------------------
Build Date: 10/2008
2009 E90N 328xi Sedan 6 Cyl
Engine code: N51
AT: GA6L45R/GM6
http://s101.photobucket.com/user/lho...in/library/E90
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