:thumbup:

Ok, found the answer to my query in an old thread. Weasel pointed out in that thread that the shredded spline issue does not affect Xdrive
http://www.xoutpost.com/bmw-sav-forums/x5-e53-forum/63004-transfer-case-removal-pictures-6.html

"The older one can have the chain slack problem like this thread, and the front output shaft splines can strip on some of them as well. The x-drive is not going to have the output shaft splines problems and is not going to have the chain slack problems... because all the abuse gets thrown to the clutch pack, which is what wears on them causing replacement costs.
Pretty much either one is just as likely to get worn to the point of repalcement over the years. But that is with anything with a transfer case. I've repalced them on fords, chevys, dodges, jeeps, etc. Unavoidable costs of having a 4 wheel drive vehicle."

"short" front drive shaft
 

Here's the Central American solution to the "short" front drive shaft problem... can't vouch for how sound this is mechanically but its a pretty simple idea....

http://www.xoutpost.com/members/jwil...53-photo-4.jpg

http://www.xoutpost.com/members/jwil...51-photo-2.jpg

The simplest solutions are often the cleverest; they are also usually wrong.

I have a 2006 X5 3.0 6sp Manual Trans with 113K miles.

Questions:

1. Does anyone know when (roughly how many miles) the clutch pack goes out on the ATC500 transfer case?

2. How much and who do you use to rebuild the Transfer Case?
Is it a DIY with the rebuild kit?

I only know about the actuator gear stripping/failing on the ATC500 transfer case.

NV125 has its own problems with short driveshaft, chain slack, etc.

Out of my curiosity, has anyone here dumped the Transfer Case/Front drive shaft, then find a drive shaft long enough to hook up directly to the Transmission, thus converting AWD ---> RWD vehicle?

Count me into the desplined club. Not fun. I'm trying to get in touch with Tom. This is a great old thread and I'm happy to dig it back up!

Why would anyone do that? Do you have problem with your transfer case? Unplug the cable to X-Drive transfer case and you will be RWD only. You will lose DSC though.

Bringing an old thread out of the grave. I am tasked with a 2005 4.4L (2-14-2005 production date) E53 X5. Report is a metal to metal noise and doesn't drive in either drive or reverse. I had read early portion of thread and hoped it was the classic sheared splines on front driveshaft. Later in thread, i read that the design changed before 2005 to where it is x drive now.

So where would be the places, things to check on with this 2005 please? I am newb to E53 X5 but have owned 2 diesel bmw (E90 and E70) so not a newb to working on BMWs. I have intermediate mechanic skills but that is a realtive judgement thing. I switched out the diff on the E90 to go to a LSD Wavetrac if that better clarifies. thanks

Most likely a front drive shaft popped out of the front diff...