Xoutpost.com - Transfer case removal pictures...

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I made some pretty good progress tonite:

Tight spaces when I am working at night with the garage door closed.
http://i356.photobucket.com/albums/o...1/IMG_9159.jpg

Borrowed a deep 36mm socket from a friend.
http://i356.photobucket.com/albums/o...1/IMG_9193.jpg

Got off the nut from the flange, then used a 3 jaw puller to get the flange off
http://i356.photobucket.com/albums/o...1/IMG_9160.jpg

Case is still together very tight, so I got out my favorite Harbor Freight tool, the gear puller set:
http://i356.photobucket.com/albums/o...1/IMG_9192.jpg

The rod threads fit perfectly into the threads in the case
http://i356.photobucket.com/albums/o...1/IMG_9161.jpg

Finally, after being ever so gentle with it, I heard a slight pop sound....
http://i356.photobucket.com/albums/o...1/IMG_9162.jpg

http://i356.photobucket.com/albums/o...1/IMG_9163.jpg

Some kind of device to prevent the chain from hitting the case/prevent falling off?
http://i356.photobucket.com/albums/o...1/IMG_9164.jpg

Transfer case details
http://i356.photobucket.com/albums/o...1/IMG_9165.jpg

Planetary gears transmission input
http://i356.photobucket.com/albums/o...1/IMG_9166.jpg

This is how loose the chain was
http://i356.photobucket.com/albums/o...1/IMG_9167.jpg

http://i356.photobucket.com/albums/o...1/IMG_9169.jpg

Needle bearings in the cover over the back of the front output shaft
http://i356.photobucket.com/albums/o...1/IMG_9170.jpg

Needle bearings in the cover for the trans/rear shaft
http://i356.photobucket.com/albums/o...1/IMG_9171.jpg

Chain was making contact with the pad
http://i356.photobucket.com/albums/o...1/IMG_9172.jpg

Took the planetary gears off
http://i356.photobucket.com/albums/o...1/IMG_9173.jpg

http://i356.photobucket.com/albums/o...1/IMG_9174.jpg

The spacer and needle bearings in the top left corner of this next pic came out while I slid the bigger gear off the shaft.
http://i356.photobucket.com/albums/o...1/IMG_9175.jpg

http://i356.photobucket.com/albums/o...1/IMG_9177.jpg

Had to remove the pad to get the chain off the smaller gear
http://i356.photobucket.com/albums/o...1/IMG_9179.jpg

Chain comparison:
New (lighter colored)chain is so tight it doesn't bend as much as the old (darker)one
http://i356.photobucket.com/albums/o...1/IMG_9181.jpg

http://i356.photobucket.com/albums/o...1/IMG_9182.jpg

http://i356.photobucket.com/albums/o...1/IMG_9183.jpg

Transmission input shaft taken out to put on new chain
http://i356.photobucket.com/albums/o...1/IMG_9185.jpg

New chain is so tight, the big gear is hard to go back in (without removing the smaller one)
http://i356.photobucket.com/albums/o...1/IMG_9186.jpg

Since I want to remove as little as possible, I 'help' it a little
http://i356.photobucket.com/albums/o...1/IMG_9187.jpg

In and nice and tight
http://i356.photobucket.com/albums/o...1/IMG_9188.jpg

Planetary back on.
http://i356.photobucket.com/albums/o...1/IMG_9189.jpg

Need some sealant like what was on there before, some grey stuff....this maybe?
http://i356.photobucket.com/albums/o...1/IMG_9190.jpg

DAMMMMmmmmm, the sealant is dried up, so close yet so far....anyway, I feel good about getting into the case and getting the chain on.
I was so anxious to get the case back together I started getting Krazy!!@#$
http://i356.photobucket.com/albums/o...1/IMG_9191.jpg

OK, just kidding....I will call it a night for now.

P.S.
I found out from RealOEM.com Online BMW Parts Catalog that I can buy the exhaust stud as a dealer part ($2.50 from PelicanParts.com), so I will use a socket and a C clamp to try and get the broken one out.

(They also have all the shaft seals for the transfer case, just in case...)

Great work...I am replacing the transfer case myself on an ML 430

Dville how many miles do you have on your X5?

what were the symptoms leading to your belief in changing the transfer belt

Quote:

Originally Posted by X_5 (Post 634218)

Dville how many miles do you have on your X5?

111,000 miles. Former certified pre-owned.

Quote:

Originally Posted by jst2878 (Post 634435)

what were the symptoms leading to your belief in changing the transfer belt

From a standing start, floor the pedal, and you would hear a cracking noise from drivetrain. Sounded like either driveshaft splines were slipping or similar. I verified the shaft was not slipping, so the only "slippable" part left was transfer case. When i found out a chain was inside, that seemed to be the culprit.
From a standing start, take off gently, and you won't notice any problem.

More weight in car, or uphill, it will happen easier.

Nice. If you weren't taking pictures, I'm sure the job would have been a lot quicker.

Dude you are my hero!
Excellent write up and pictures, I can't wait to see the finish!

You don't "see" the finish. This isn't a bling "mod."