Question About Transfer Case Actuator Gear
 

Hello I've decided to replace my actuator gear since my car is giving me problems and I'm wondering if I should buy an aftermarket metal one or an OEM (plastic)

on paper, it makes sense to choose metal over plastic but at the same time the original transfer case actuator gear lasts a long time till it fails so im not sure which one would be a better pick:dunno:

With MTBF of 100,00 miles or more I would personally rather wear the plastic gear than worry about wearing out the drive gear on a harder metal gear.

What would be the difference if you don't mind me asking? I would expect the metal to last longer than the OEM one

Failure is usually due to a low amount of grease over time. A new gear was installed on mine shortly after buying it. It had the trifecta lights on. The gear was worn out on one side. A carbon fiber gear and high temp synthetic grease fixed it right up.

You are introducing a big unknown. If the new big gear isn't a perfect mate with the drive gear you risk it warning out the drive gear. It could be perfect and last a million miles it could be 1/10th of a % off of perfect and chewb away the drive gear in 2000 miles.

I like the idea of the carbon fiber.


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The factory set up has very little grease. I drowned a carbon fiber gear in high temp synthetic grease. The new gear is slightly wider too. I can tell you it works. You can feel the Xdrive working. Especially in rain and take off.

My original gear failed at nearly 300 tkm. I turned the gear 180 degrees, cleaned debris and re-greased. It has now lasted another 100 tkm. Nowadays the gear is also available as original BMW part.

My original gear failed at about 250,000 miles. Replaced it with a carbon fiber reinforced plastic gear. Been about 30,000 miles and still working fine. I expect the car will be done before the gear is.

Same as others. CRP gear that was heavily lubed. Been good for ~30k miles now. Original failed at about 100k.

After reading a few responses I like the idea of carbon fiber but I already bought the metal gear, if anything fails or breaks I will definitely buy a carbon fiber gear next time unless I should just switch to carbon fiber right now