Faulty transfer case...FIXED!!!!!
 

Hi everyone,

I had the trifecta of lights appear but no real warnings that I have read every where online. My only possible indications was at random times under hard braking would I hear this awful grinding of metal and gears but this only happened twice in the last couple of years and no warning lights. So below are the codes I was given from the dealership

2006 X5 3.0 sport package
Vehicle mileage 169000
TC oil was replaced at 166000

VTG 539E Transfer Case Malfunction
VTG 54C4 Calibration Faulty
DSC 5F3A Transfer Case & Special Transmission: Malfunction

1. How do I disable my Transfer case so that I am in RWD only. Due to high cost of replacement part of the Transfer Case and low funds at this time.

2. Should I repair my Servo Motor gear as well although I cannot say whether I heard the tell tale sign of the clicking.

UPDATE

Today @4pm ish I dived in was able to remove the TC actuator. The second little clip was a pain but finally got it. The gear inside was worn down and since I didn't order a new one I just flipped 180degrees. Took her out for a drive and no lights!
I spent 4 hours from taking it out to replacing back in vehicle half the time was spent re watching the video's regarding the c clip had a heck of time removing and replacing.
I believe she had combination of problems, TC oil needed to be changed, TC actuator, flex disc and my rear diffs were leaking all those together she drove rough now she is smooth as silk. I realize this is a temp fix but dang I want 169K on that gear...
Moral of the story if you don't have the symptoms yet you get the code for TC malfunction always always check the TC actuator first, then troubleshoot from there.
I would really like to give a big Thank you to everyone who responded you guys are awesome!!!
http://www.xoutpost.com/images/smilies/thumbup.gif

Easy Peasy,
remove transfer case,
Tow X to custom driveshaft
Have shop fabricate a custom drive shaft from the tranny to the differential.
RWD all the time.

:rofl:

Definitely try replacing the transfer case motor gear before all else. It is around $12 and might do the trick. After that, you need to figure out if it is the front driveshaft stripped out or the actual transfer case. If you do need a transfer case, used ones can be found for around $400.

I don't know about disabling it long term. I think You would lose the safety of the anti-lock brakes and stability control.

It concerns me that you just replaced the TC fluid 3000 miles ago since I also have a 2006 3.0 and just replaced my oil about 2000 miles ago (@144k).

Was this change done to try to address this issue or just preventative?
Did you use the OEM fluid (really expensive stuff)?
Have you rechecked the level since the codes?

Anybody else have TC issues shortly after the fluid change?

Thank you David.X5

I will try that first and flip if necessary to see if this works. Seemed when people did post of a worn gear they used the 5F3A but I did not find the other 539E code...
I am newbie mechanic so I learn as they break...I just had my flex disc replaced at the 169k. I did not do the work myself. Would the worn disc cause the driveshaft to strip out the TC?

mtthmpsn,

I gave the short straight to the point version. My own ignorance of not knowing how awd works needs fluid there as well, sides the engine, coolant, etc. I take my car to the dealership for oil changes to have them service and look the car over tell me what needs to be fixed. No one in the whole 110k mileage of ownership has mentioned to change the TC oil when visiting the dealerships. The X was CPO so I made sure to use that policy before it expired. So I would not be concerned that changing the oil will affect your vehicle, not changing/refreshing the oil imho will.

That being said the lights came on after a visit to a tire center. They had my baby dangling at angle ass up front down instead of the usual flat level. I was having my tires balanced and properly inflated. I know this should not be the cause but this action is what flicked all the light on. Before this visit I had no real indications except for one slip but I chalked it up to my driving and the rain. Flipping a U and flooring it as the pavement was wet after being dry for awhile I took it for several diagnosis from different places because I was not satisfied with the answers form researching the forum regarding the issues. I asked the dealer to replace the fluid at the 166k when the issue first happened.

Big expensive lesson learned.

ABS and DSC should still work since the wheel sensors are still retained. The ABS module will still receives the signal and the ABS pump will still lock and unlock each individual brake calipers to control the wheel speed.

Got it. Thanks for the clarification. That makes me feel better about changing mine. Sorry I can't offer any assistance with your issues, but good luck and let us know what you end up doing and how it works out.

Did the lights come on immediately after the tire balancing?

Yes, when they pulled the car to curb I got in and was like what the hell?! I drove to a parking space a few feet drove like crap and turned it off waited 5 min turned back on lights off drove away then 20 min later of driving lights back on.