Oh Dear.. There goes the Gearbox!!!

[Steamyrotter]

Pprior to struggling to get the box in the car (its now up in the chassis but held in with 4 bolts before it got too dark...), i checked the chain through the drain hole.
Nice n tight with very minimal play.
Fluid that came out was still reasonably red and clear so happy it will be OK for while yet.




I hope.....

[Weasel]

You have an 03, so pre x-drive... The fluid holds up very well in them. The only problems usually seen are the front output shaft splines stripping or the chain getting some slack. The splines aren't all that common, but still more common than the chain slack.

[Steamyrotter]

Yup pre x-drive

The chain felt OK through the drain plug.
The front prop was stuck on the transfer box but it finally came off so cleaned and greased the splines

will finally be filling up the fluids today so will have a poke through the filler to ensure the chain is as i think it is. (or hope it is....)

Thanks for your advice
Much appreciated

[Weasel]

You did a good thing by cleaning and greasing the splines. I think one of the things that contributes to the splines failing is not only lack of grease, but they put the damn ac drain hose right above it on some years which drips water directly on the slip-yoke! If the yoke is hot and cold water drips on it, it could theoretically cause condensation to form in the splines, especially in the absence of grease. I moved my ac drain over, loosely cable tied it to the shifter cable on the trans just for peace of mind.

[Steamyrotter]

Well final update (I hope!!)

Now got it back on the road .
Pulls like a goodun and the cooler is doing the biz.
Well happy and thanks to all who helped.

Here are some piccies of the spring and my repair method....
Also a nice view of what goes into the GM5L40E

[[email protected]]

well done mate ,i see there was no linings left on the friction plates and the sirclip groves where still in good condition

[x555a]

WOW ......Great thread and thanks for sharing the pics..........and to think i thought i was brave/stupid for changing my cv boot and subframe bushes but this takes it to another level.

[Steamyrotter]

Lol
Thanks bods

Just a wee update.

Just got back from a weeks hol with the caravan (1750kgs 26ft twin axle) 140 miles each way (down to cornwall so not that flat!)

Pulled it with out a second thought.
(Well admittedly the wife drove it there, i drove it back )



Certainly one way to test your workmanship.


I was surprised by the general good condition of the internals apart from the spring and some clutch packs.
I like stripping things and seeing how they work.
It really is a bonus that it went back together and even worked afterwards


I have the pleasure of a front left CV boot to do next...
then poss a wheel bearing and.............


Oh and angel eyes to fit one day......
.....
etc

[rares]

Hi ,
it looks like u know something about trans and I was wondering if u could helpme w/ some tips ? last year I had to replace the transf case and the front drive shaft ...but I still hear that noise(bang) under the car when I on/off the gas pedal or if I bring the car the stop.I lifted the car and I noticed that the wheels have too much free rotation before to engadge the drive shaft ...it's the front diferential's fault , any chain slack ? and how to fix it ?thank u

[Steamyrotter]

Well not being an expert in the field i can only offer my opinion.

I would check the play from the front prop to the front wheels. if there is too much then the front diff will be the problem.
looking at realoem (RealOEM.com * BMW E53 X5 3.0d Final drive (front axle), parts, 4-wheel) there isnt too much detail in there..
Usually (in my experience) there is a certain amount of play in the diffs but shouldn't be excessive. you can open them up and re shim them to take out the back lash but will need to take the diff out first..

If there is a lot of play between the front and rear props then there is an issue with the transfer box. Do a search on here for transfer chain and you will see that it is not unusual to have a slack chain which could cause the noise.

Check all rubber components as a damaged doughnut can also give that thump.