transfer case actuator issues. need advice please!
 

ok guys, I know the actuator is bad. I had the clicking noise and the dcs/abs/brake lights on. it now pretty much will come on immediately after i start driving.

It seems to drive just fine other than that. My question is, is it ok to drive it like this till i can replace it?

A new one is $900. I thought my warranty would cover it but it won't..
Also, if i have mine rebuilt, will it still need to be coded???

I'm looking for the cheapest possible way to do this. I will do it myself but I'm not sure if I can get to it for a few weeks. I just don't want to do further damage..

thanks!

i have read that you can take the unit apart and invert the gear, apparently this then uses an undamaged part of the gear, (not first hand experience so no gurantees)

i also have read that you can disconnect the actuator and simply run in 2 wheel drive

SlickGT1 flipped his gear around. Maybe ask him how its holding up.

http://www.xoutpost.com/bmw-sav-foru...ixed-sort.html

aren't I already driving in 2wd when the DSC/abs/brake light are on?

I want to fix it before winter for sure... Isn't there are rebuild kit somewhere????? I would rather do that with my original actuator so i don't have to re code or spend 900.

If you search, there was a guy selling the gear made of metal. Not sure if he's still selling or if another option is available.

Here is a place that is testing and says soon selling them. YMMV.
The instructions are good.

Transfer Case Actuator Motor Gear
( view PDF instructions ) ( view instructional video )
This gear is located inside the actuator motor. We manufacture using a high temp nylon carbon fiber reinforced material which is self lubricating. Warranty subject to proof that all four tires replaced at once. See warranty section of website for further information. OE # for assembly: 27 10 7 566 296 Old #: 27 10 7 541 782 See our How To page for video instructions ***Currently in testing phase and should be available for purchase around 24 October 2012***
$125.00
Available Soon

Odometer Gears - BMW - X3 (E83-N) - X5 (E53) 1999-2010

^good find! I'd be willing to give it a go for $125. Beats $900 for a new actuator motor with the same gear that wore out the first time.

Awesome!! Thanks a ton! I can wait till October.
I'm going to call ASAP. This seems to be a problem with more and more
X5s as they get older. Beats 900 bucks plus coding.

Just flip the gear. I fixed mine in April, and all has been fine so far. That is the cheapest fix, and will take you 15 min. I have been off roading a bit since then, and quite a few hard starts, to the point all 4 wheels peeled out. The fix seems to be holding up. I mean, at least it will prolong the life of it. Rebuild it when you have no meat on the gear. For not you have 50% of the gear in excellent shape.

Oh as far as I know, once you peel off the gear protecting plate, it does not go on the same way. You basically mess it up, and I bet they just glue it back on, not press fit it. That is one of the reasons I decided to just flip the gear for now.

And there are guys rebuilding these things on ebay. Even the guy with the brass gear.

This is a good find though. People should take a look at it to see the video. The part where they remove the C clip, that step will be a bitch to re-install the C clip. Then where he pops the metal cover off, that is BS. I did a lot of searching, and most people seem to mess the cover up. You really need to be careful in doing this part. You bend that cover, nothing is going to make it fit right again.

When my gear fails again, I am going to try to rebuild my actuator. But I have time. So no worries. Hopefully someone else tries it before me.