I would have said "I can't wait to hear about the finish" but he provided such awesome pictures throughout the process, so I would expect we will see the finish, or who knows a You Tube video of a him stomping the gas, lol.

LOL yes, let's hear it!

I was just joking, BTW.

I only hope I never have to print this thread for use..

You are damn right.

I have gotten so much help from x5worldcom.com and E38.org that I thought I owe it to give back to the community.
I posted pictures like what I would want to see if I had a problem and wanted to know what was involved in the repair, to see if I wanted to tackle it or not....

Hope I helped someone....

Well, here is the last chapter....

I ordered one flex disc from Pelican Parts in CA, and the other from Above All Motorwerks in IL. 2nd day air so I could finish faster.....
What do you know. The boxes came from the SAME warehouse!!! (the Pelican box has some extra tape on it)
http://i356.photobucket.com/albums/o...1/IMG_9227.jpg

http://i356.photobucket.com/albums/o...1/IMG_9228.jpg

http://i356.photobucket.com/albums/o...1/IMG_9229.jpg

Same invoices
http://i356.photobucket.com/albums/o...1/IMG_9230.jpg

http://i356.photobucket.com/albums/o...1/IMG_9231.jpg
Difference is customer support, I called above all, and get a recording saying they are at the racetrack, Pelican sends you an email every step of the way....
Above All was cheaper, adn I only used them cuz Pelican did not have the front flex disc in stock (whatever that means, since Above all sent me one from the same place).

Anyway, I ordered a front and rear flex disc (guibo, or Universal Joint) and 3 exhaust manifold bolts.

http://i356.photobucket.com/albums/o...1/IMG_9232.jpg

The flex discs are the exact OE and you can see where they actually used a grinder to grind off the BMW logo so they can sell it as aftermarket. (FEBI brand)
http://i356.photobucket.com/albums/o...1/IMG_9234.jpg

BMW part number sanded off
http://i356.photobucket.com/albums/o...1/IMG_9235.jpg

Getting everything back together, and broke the new exhaust bolt again.....too excited I guess.
http://i356.photobucket.com/albums/o...1/IMG_9238.jpg

http://i356.photobucket.com/albums/o...1/IMG_9240.jpg

New flex disc in place
http://i356.photobucket.com/albums/o...1/IMG_9241.jpg

Exhaust back in place
http://i356.photobucket.com/albums/o...1/IMG_9242.jpg

Shields too, oxygen sensors and wiring carefully put back...
http://i356.photobucket.com/albums/o...1/IMG_9243.jpg

Transfer case in place
http://i356.photobucket.com/albums/o...1/IMG_9244.jpg

Front shaft lined up same as it was removed
http://i356.photobucket.com/albums/o...1/IMG_9245.jpg

They instruct you not to run without the stiffener plate, since the bolts that hold it in place also hold down the stabilizer bar.
http://i356.photobucket.com/albums/o...1/IMG_9246.jpg

http://i356.photobucket.com/albums/o...1/IMG_9247.jpg

Sensor wiring put back
http://i356.photobucket.com/albums/o...1/IMG_9248.jpg

Damn you....
http://i356.photobucket.com/albums/o...1/IMG_9249.jpg

I see the replacement bolts are not exactly a match to the BMW bolts, since the grip splines go all the way down the wide part of the shank, not like the factory one on the right.
http://i356.photobucket.com/albums/o...1/IMG_9250.jpg

http://i356.photobucket.com/albums/o...1/IMG_9251.jpg

Ready to fill transfer case with ATF/
http://i356.photobucket.com/albums/o...1/IMG_9252.jpg

Filled it with less than one quarts worth of pumping before fluid was running out of the top hole.
Tightened fill plug, and lowered SAV.

Started her up for the first time in over 1 week (yeah, I work slow)
http://i356.photobucket.com/albums/o...1/IMG_9256.jpg


Took it for a spin. (it's raining).
I punched it from a standing start many times, and no noise while I give myself whiplash....
Problem seems to be solved....I'm HAPPY!!! :)

Congratulations!! What a great write up - I wish you never to have another repair on your ride!!

Just got back from a 110 mile trip with the family in the recently repaired X5 (less than 3 hours after lowering the truck, we were on the road.)
Everything works as expected, and I can drive off normally from traffic lights again, without having to feather the throttle like a girlie man...

Excellent write-up dville! I'm sure that I will be referring back to this at some point in the near future. Sorry to hear about the exhaust bolts. Reminds me of when I had to replace a few turbine housing studs on the car. Fun times. :p

Is there an OEM gasket for this? I dont feel like doing all this work just to find out the form-a-gasket leaked.

http://i356.photobucket.com/albums/o...1/IMG_9195.jpg

No gasket was there from the start...
If you look at it untouched, you will see the sealant bead around the new transfer case.