X3 E83 Transfer case re-build.

[shanbala]

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Finally, after reading the numerous forums on the world wide web on X3 transfer case problems, I took the decision to "rebuild" my transfer case on my 2006 2.5Si X3.
Before taking this step, carried out cheaper alternatives (change oil, reprogram) but sadly symptoms reappeared. I had my ride diagnosed by 3 different reliable/recommended mechanics. Had 3 varying opinions but with some similar diagnosis.

As part of the rebuild decided to change the transfer case chain, two main sprockets (sprocket driven & drive sprocket), friction plates 6 pieces (referred as clutch plates by my mechanic), and the gasket kit. Parts were purchased online.

Total cost (parts only) USD $606. With labour & miscellaneous other cost to be included, I am expecting a final cost of RM 3,000 to RM 3,500. This amounts represents a saving $$$$ as opposed to a new transfer unit of RM 15K from AB. Not sure if used or recon units are readily available in Malaysia.

Been advised that all parts have been installed, transfer unit cleaned & reassembled and remounted. Once the car is returned back to me within the next 24 hours and after "breaking-in" the transfer case, only then can the "re-build" be hailed as a success. Initial testing is encouraging.

 

[Xthree]

look forward for your good results ... keep us posted bro .

 

[digerati]

Am interested with the results too. Looking forward.

Did you do it yourself at home? It's not clear from your posting. Really curious.

 

[shanbala]

Good evenings guys,

It has been 2 days since the repairs. Not many miles clocked so this will the first impression of the re-built
- gear selection very very smooth
- gear change hardly noticeable and smooth
- on acceleration, car seems more responsive
- no hesitation when slowing down and no lag feeling

Overall I am very, very happy with the re-build and monies well spent. Waiting for the right opportunity to really put the gear box through some 'hard' driving. Due to the condition of my tires, I need to wait a few more weeks before carrying out this task. Planning to change all 4 rubbers but like 2 years ago having difficulty in securing the correct combination for my staggered 19" set up. A trip to S'pore seems in the horizon. The "home office" seems happy with the outcome as she is the daily driver. I'm only the weekend driver.

In summary right decision to rebuild. Can't wait for new rubbers. Will provide further progress updates in few weeks time.

Digerati, answer to your question - the rebuild was done by my regular mechanic who maintains my X3, E60 and E30. Sadly I have no confidence to carry out such DIY jobs. Thanks to the many forums I visited, I knew what I was getting myself into and also ensured that I purchased the rights parts online.How did we live before the the existence of the World Wide Web !!!!

 

[digerati]

Sounds good bro. RM3500 including labour sure does sound reasonable.

Let's say if I'm interested to go down your path too, would you mind sharing the details of the purchases and labour costs? Over a cup of coffee maybe one of these days?

 

[shanbala]

Good afternoon digerati,

Anytime convenient to both of us I will gladly share all pertinent details with you. Forums such as these are there to help other members. When I posted my re-build plan, it was to let other X3 owners know this option is available. The more I drive the car, the more satisfied I am that the rebuild was and most likely can be classified as a success.
Contact me on 0172352099.

 

[bmw7833]

Good afternoon digerati,

Anytime convenient to both of us I will gladly share all pertinent details with you. Forums such as these are there to help other members. When I posted my re-build plan, it was to let other X3 owners know this option is available. The more I drive the car, the more satisfied I am that the rebuild was and most likely can be classified as a success.
Contact me on 0172352099.

A good sharing!

Bro, pls share where u purchased the parts from? And where u send your ride to replace the parts? I might doing the same way like you now.

How long the x3 with u? Since year 2006?

 

[shanbala]

Good day bro,

My X3 is a 2006 manufacture, recon from UK. The previous owner bought it as a recon in 2010 and I purchased it in October 2012.
Thus, I have been having this ride for 3 years ++
The transfer case model for the 2006 model is ATC 400.
The parts were purchased from
(1) Cobra Transmission (USA) - Transfer Case chain, Drive Sprocket, Sprocket Driven and Seal Kit
(2) E-Bay - friction plate - supplier in Belarus

The rebuild was done by my regular mechanic who maintains my cars.
Forward me an email address so that I can send you some images of what these parts look like. I cant seem to attach the images here.

Be advised that attach to the transfer case is the actuator motor. There is a specific gear within this motor that tends to wear off over time. This gear can be purchased separately and replaced. I too purchased the gear but as there was no error message, my mechanic told why repair something which is not broken.

My advice would be get the ride checked out properly, understand the issues and than decide if the transfer case is the issue. Hopefully it is as simple as a sensor malfunction.There is a lot of info on the internet which were very useful. The transfer case on the X3 appear to be an issue going by all the comments on the various forums. Saying this, for every one complaint, there are many owners who are totally happy with their ride. Buzz me if you want to chat further 017-2352099

 

[bmw7833]

I heard that we can "bypass" the transfer case?

 

[shanbala]

Transfer case "bypass"

While doing my research in 2014, did not come across such a suggestion in any of the overseas forums (maybe was not looking for such a solution)
I will be surprised that this is possible.
The driveshaft is connected to the transfer case and as such how do we "bypass" ??

 

[bmw7833]

Transfer case "bypass"

While doing my research in 2014, did not come across such a suggestion in any of the overseas forums (maybe was not looking for such a solution)
I will be surprised that this is possible.
The driveshaft is connected to the transfer case and as such how do we "bypass" ??

I am not sure but i heard from my mechanic that a lot of X5 bypass the transfer case by "disconnect a cable"?

 

[gimli]

no, i don't think it's possible. in the x3 or x5 you can't choose to disable 4x4, it's done automatically (on-demand all wheel drive). I think it only can be done if it were a selectable all wheel drive system (e.g pickup trucks)

Also the 4x4 is interlinked with the DSC and ABS. The transfer case design in the x3 is actually quite simple. A lot of times, changing the transfer case oil helps.

 

[gckiat]

transfer case can be bypassed by disconnecting the shaft from transfer case to front wheel.
alternatively u may remove some fuses.

 

[gimli]

could you provide proof? remove some fuses!!?? you do know that this is a BMW X3 rite?? the electrical system is very complicated.

as far as I know, it cannot be done, the way the 4x4 system is designed, no way it will work. read the above post that i made

 

[Alfred Chen]

rebuilding my x3 F25 transfer case at OPTIMUM MOTORWORKS kayu Ara now...it will take few days, praying hard for everything going smooth.