Ok. I'll see what I can find out. Thanks.

Update: I've narrowed it down to the dreaded front drive shaft spline issue. I am trying to remove the drive shaft now, but it isnt wanting to come out. I did a search for a DIY and I really didnt come up with anything. Does anyone have a good walkthrough on how to remove it?

Lots written about those drive shafts.

Start here.


http://www.xoutpost.com/bmw-sav-foru...t-problem.html

Some pics here.


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

You have to decide how deep you go. You can get a new or used BMW driveshaft, and swap those out without touching the transfer case or you can get a version with longer splines from a few places. That will require at least loosening the transfer case and likely require removing the transfer case to get clearance.

Thanks. I'm going to get the extended drive shaft and go that route. My problem right now is getting the old shaft out. It seems I have to split the tray and TC to get it out. Unless there is another way I am not seeing.

If you have a standard length spline, this is the general method to get it out. You should not have to remove the TC (install with the longer splines is different).

1) Remove the 6 bolts on the front rubber Guibo.
2) Use muscle power or some sort of lever to slide the front driveshaft back into the transfer case. If the splines are really bungled up, this may be hard to impossible. Hopefully they will still slide for you.
3) After you get a little movement, you should be able to free the rubber Guibo
4) Once the Guibo is out of the way, you should be able to wiggle the driveshaft out.

Two suggestions - if you are removing the TC to replace the front driveshaft, I would check the TC chain for stretch and replace while you have the chance. They are not expensive and do stretch with use. Easy job once the TC is out of the car.

I also found that the center support bearing on the rear driveshaft was really sloppy once I started taking things apart on mine - its another wear item and worth checking.

Yeah. I'm having an issue with moving it back enough to get the Guibo out. I'll keep working on it.

Great idea on checking for chain slop while I'm at this stage.

Pry bar. You need to pry it back as it won't easily move, especially one that has lived in a place with inclement weather. Mine was a San Fran to Vegas X5 and the splines were orange colored with a light surface rust. Grease the splines when you put your new driveshaft in.

BTW: can you do to advanced edit and change the title to be more descriptive of the problem? It'll help others in the future...

And...now is a great time to put a signature (look in the User CP).