Thanks for the great write up. Replaced my chain last night without removing the transfer case from the X.

BMW X5 TRANSFER CASE (rebuilt) With drive shaft refinish
 

Front Drive Shaft from t-case to diff $300 1 inch longer

just finished replacing the chain. Transfer case reinstalled. the only problem I am having is removing the two broken exhaust studs. Used hammer with no luck. Any help or ideas would be great. Thanks for the write up. Took 10 hours taking my time.

you may wanna buy a torch flame from home depot and a punch chisel and a hammer pictures attached good look do it slow and nice (exhaust stud buy em at bmw dealer part number 11621704717

Great thread!

got her done. I forgot how much power my 4.4 has as I have been babying it for months now. Thanks for the great write up, everything worken perfect.

So is the general consensus that its 'ok' to drive it with a stretched chain for a while? Could someone do a DIY for this without removing the transfer case from the car? I'm about to purchase a 3.0 MT5 that I believe to have this issue.

BTW I used my 36mm oil filter cap socket for the TC output bolt. 2001 4.4, 140,000 miles

Guys, what is the torque for the E12 torx bolts on the transfer case and what was supposed to be on the shaft splines, grease or NeverSeez that it is an anti seize & lubricating compound?
It doesn't look like the original stuf is only grease.

Guys, quite a few of you opened the transfer case already. What is the torque for these bolts so I can finish the job. I couldn't find this info anywhere but I went by the size and figured that 30NM is good enough. Can you please post what torque you used for the transfer case bolts?