2005 BMW X3 TRANSFER CASE REBUILD -DIY
 

This weekend I rebuilt a friend's 2005 BMW X3 transfer case. BMW wanted to charge her over $3000 for a new one. I bought the bearing kit from cobra transmission $98 and the new chain $89 from american power train warehouse. All in it cost just over $200. Don't know if it'll help anyone out or not, but I figured I'd post it.

https://www.youtube.com/watch?v=AzhznwiSLBA


Thanks,
Sean

Thanks for doing the video Sean. Wish you had a camera stand & could of shown the actual disassembly & assembly, but GOOD Job. What gray sealant did you use?

I used Permatex Ultra Grey.
Also, as far as the dis assembly. It's really quite simple. There are a few snap rings and that's it. If people take on this job, I would recommend you go out and buy Lisle heavy duty snap ring pliers. They'll make your life a lot easier and really make the job easier.

Can I assume all bearings are pressed in place & need a puller to remove & bushing press to install them? What's the torque for the assembly screws?

Bearings are pressed in. You can pound out the shaft with the input bearing on it. same with two others. They all came out very easily. If you need to, buy the 12 ton bearing press from Harbor freight then return it after you press in the bearings.
Torque for the screws is bottom them out then a quarter turn. (this is from the guy in LA who rebuilds these transfer cases) There are no torque values listed anywhere.

Hello Sean - I am trying to troubleshoot my ATC400, and wondering should the assembly at timepoint 3:59 allow the input shaft from the servomotor to rotate a full 360, or should there be some resistance from the clutchpack limiting the rotation? I've replace my servomotor and ECU, get the TC still will not calibrate. Debating if I'm going to drop the TC or just send the car down the road. Great video!

Somewhat same as above. Thanks for posting[emoji106] by doing so...youve helped many others...this means good fortune for you and your car[emoji41]

Sent from my SM-J727T using Tapatalk

I may have similar issue...did you ever resolve yours?

Turns out my whole clutch pack inside was shredded. I was lucky enough to find an X3 on FB Marketplace being parted out, and picked up that TC for $100.. Swapped it out, calibrated stuff with ISTA and all was great! Took longer to drop the exhaust and drive line than the actual TC swap.

Here's a vid I did on the specific instance, so hopefully some help..

https://youtu.be/0-xZ3-8hh8Q?t=583

I don’t have a free wheeling shaft where the actuator connects, did you have a force too high code? I can turn the shaft with my hand and there is some resistance it’s not significant but it’s not nothing either.