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.

There isn't anything I can think of associated with balancing the rear tires that would be the cause of your problem. Always take the position there are no coincidences. You have mentioned the trifecta but not that you have any additional indication of a problem when you left. Is the only new thing the lights? Do you have air suspension?

Does the ATC transfer case send torque to any wheels for forward movement if one wheel (via halfshaft or driveshaft failure) is disabled? The grinding sound is concerning, but in an NV (early build) transfer case, the car stops going forward at all if there is a driveshaft or halfshaft malfunction that causes a no spin circumstance to ANY wheel.

bcredliner

No air just springs
The lights are the only thing and she sometimes drives like crap since the lights came on but since the flex disc was replaced that has made a night a day difference in driving I still notice sometimes a hard shift from 1-2 but its not every single time I go from a stop since I got the car back yesterday not sure if thats related to TC or not. My theory was the tire shop was the last straw and my TC oil was old and cruddy. That fault code showed up as well and they did replace it but did not solve the issue. But the last dealership I took it finally cleared that fault code. The first dealership just stopped at oil is dirty new transfer case. I asked them to change the oil anyways. I had them print me the codes they said they could not clear the TC oil change fault code from appearing so I took the car back and did more research...2 indy's later the fault for the change TC oil remained, they could not clear it and again told me it needs new TC and no new codes popped up until I went to a different dealership where they were magically somehow were able to clear the TC oil code and a new one popped up VTG539E

lo jack
I don't know that much about how the transfer case works in the earlier builds. I just know I have the clutch pack and I may or may not have burned up my plates or they are at the end of line if that makes sense to you. The grinding sound is random and I have to really stomp on the brakes and even then it doesn't always reproduce.

I was hoping to tackle the car today turns out tomorrow I will be able to look into the servo motor and I'm hoping that's the issue. When I solve this issue whether it's both my servo motor and TC I will update. Thank you everyone for your input.

Infrequent symptoms with no consistent circumstances are very difficult to diagnose. The hard 1-2 shifts are likely related to the transmission. Codes can be misleading. Since the BMW dealership replaced the fluid it would seem it is the right stuff and they filled it to proper level. Just in case, I would check the fluid level. When you remove the plug the fluid should run out a bit or be flush with the hole when the vehicle is level.

My guess is the trifecta is directly associated with the balancing. They could have damaged an ABS sensor wire or connector as an example. That would have nothing to do with the transfer case. The transfer case code may be a separate issue that isn't to the point where there are the usual symptoms. My thought is the gear is wearing out as has been mentioned but could be otherwise. I have heard nothing that indicates the transfer case needs to be replaced. I don't think the solution is going to be costly.

I'm going to say that the transfer case issue is likely related to that plastic gear in the actuator. Our 2005 X5 3.0i had similar intermittent symptoms with the DSC light staying on. It would stay off for days or weeks, until I had the pleasure of working on the car.

Something about lifting it off the ground to do an oil change would set off the DSC issue with the transfer case.

I removed the actuator, replaced the gear (it was chewed up), and re-installed along with drain and fill with new transfer case fluid from the dealer. That was 7 or 8 months ago, no problems since!

Video DIY of this to come soon.

bcredliner,

I really hope its just the actuator myself too. I had been to that tire location many times before so unsure why the guy thought it was a good idea to not place my vehicle level with ground that time.

richardb,

I am curious do you have the fault codes that were triggered. Post that video I would love to watch it I am just slightly nervous about this work because right now she's my only working vehicle.

does anyone know how to remove the to remove the smaller secondary wire connection without yanking and breaking

Is there any more to this diagnosis?

For my issues it was dirty transfer case oil, the actuator gear needed replacement, along with new flex disc and my differential oil rear needed changing as well. She runs great now, I just have regular maintenance that needs to get done.

Thanks for the update.

Forgot to reply to this until now. Here's the DIY video I promised, which resolved the problem for us as well. Hope it helps!

https://youtu.be/UR7Vv5SQvDc