Anyone replace seals on a E53 transfer case? Looking for torque specs or manual.

[David.X5]

I had a leak from my transfer case and decided to rebuild a used one and then switch it out with mine rather than have my X5 discombobulated for days/weeks/etc.

Anyway, to get to the rear output shaft seal, the output flange has to be removed which is held on by a big nut. The nut of course is recessed into a flange and no socket would fit, so an hour of tinkering with a grinder and I have an extra-thin-wall 41mm socket that fit. Torque was crazy - couldn't get it loose with my 3' breaker bar - had to use the impact socket. Which leaves me wondering how tight it should be going on - anyone done this before and have a torque spec? How about for the case bolts? I haven't been able to find docs on the transfer case.

Thanks,

David

[frozenwaffles]

you dont need to take any of these off!
once the transfer case is out, crack it properly between the two halfs and all the shafts just easily slide out allowing you to replace all the shaft seals, any bearings you so desire and also the chain. super easy...no big tools at all and not crazy bolts.

[David.X5]

Thanks. Do you have a torque spec for the bolts that hold the two case halves together?

I was able to replace the chain, replace the input seal and front output seal and inspect all the bearings without removing the rear output flange, but couldn't get to the rear output seal without removing the crazy big nut. Weird...

[TiAgX5]

The Bentley details this job with all tq specs and required sealant specs.

[David.X5]

Weird. I have a Bentley manual. Section 270 on the transfer case is 6 pages and covers removing, replacing, refilling, but I didn't see anything on opening or internal repairs.

Would you check that you have more info than that (or perhaps there is another section I missed?) If so, I want to figure out what the difference is between the two versions.