Transfer Case - Repair: Other BMW X3 E83 facelift

00 Danger of poisoning if oil is ingested/absorbed through the skin

Danger of poisoning!

Ingesting oil or absorbing through the skin may cause poisoning!

Possible symptoms are

1. Headaches
2. Dizziness
3. Stomach aches
4. Vomiting
5. Diarrhoea
6. Cramps/fits
7. Unconsciousness

Protective measures/rules of conduct

1. Pour oil only into appropriately marked containers
2. Do not pour oil into drinking vessels (drinks bottles, glasses, cups or mugs)
3. Observe country-specific safety regulations

First aid measures

1. Do not induce vomiting. If the person affected is still conscious, he/she must rinse out their mouth with water, drink plenty of water and consult a doctor immediately. If the person affected is unconscious, do not administer anything by mouth, place the person in the recovery position and seek immediate medical attention.

00 Risk of injury if oil comes into contact with eyes and skin

Danger of injury!

Contact with eyes or skin may result in injury!

Possible symptoms are

1. Impaired sight
2. Irritation of the eyes
3. Reddening of the skin
4. Rough and cracked skin

Protective measures/rules of conduct

1. Wear protective goggles
2. Wear oil-resistant protective gloves
3. Observe country-specific safety regulations

First aid measures

1. Eye contact: Rinse eyes immediately with plenty of water for at least 15 minutes; if available, use an eye-rinsing bottle. If irritation of the eyes persists, consult a doctor.
2. Skin contact: Wash off with soap and water immediately. If irritation persists, consult a doctor.

Note. Do not use solvents/thinners.

00 Safety instructions for handling oil

Recycling

Observe country-specific waste-disposal regulations.

Measures if oil is unintentionally released

1. Personal precautionary measures: Danger of slipping! Keep non-involved persons away from the work area. Wear personal protective clothing/equipment.
2. Environmental protection measures: Prevent oil from draining into drain channels, sewerage systems, pits, cellars, water and the ground.
3. Limiting spread: Use oil blocks to prevent the surface spread of oil.
4. Cleaning procedure: Bind and dispose of escaped oil with nonflammable absorbents.

Note. Do not flush oil away with water or aqueous cleaning agents.

27 00 ... Topping up/changing transfer case oil

Note. Only change the oil when the transfer box is at normal operating temperature.

Checking/correcting transfer case oil level

Undo oil filler plug (1).

Check transfer case oil level.

If necessary, pour in gear oil up to lower edge of opening for oil filler plug (1).

Installation

Tightening torque: 27 00 11AZ, see 27 00 TRANSFER BOX IN GENERAL .

Replace sealing ring.

Place oil collecting apparatus underneath.

Scheme 17

Remove oil drain plug (2).

Drain and dispose of gear oil.

Note. Observe country-specific waste-disposal regulations

Replace sealing ring, screw in oil drain plug (2) and tighten down.

Tightening torque: 27 00 11AZ, see 27 00 TRANSFER BOX IN GENERAL .

Undo oil filler plug (1).

Pour in gear oil up to lower edge of opening for oil filler plug (1).

Tightening torque: 27 00 11AZ, see 27 00 TRANSFER BOX IN GENERAL .

Replace sealing ring.

27 10 ... Checking function of front differential and transfer case

Note. Fault diagnosis with DIS Tester. Adhere to specified repair sequence in DIS.

27 10 010 Removing and installing transfer case (ATC 400 X-Drive)

Special tools required

1. 00 2 030
2. 24 5 301
3. 24 5 305

Failure to comply with this requirement will result in serious damage to the transfer case!

Necessary preliminary tasks

1. Remove complete exhaust system, see «18 00 020 REMOVING AND INSTALLING COMPLETE EXHAUST SYSTEM (M54)»(ref-202780-S16724099112005102900000) .
2. Remove heat shield.

Unfasten screws.

Tightening torque: 26 11 9AZ, see 26 11 PROPELLER SHAFT, COMPLETE .

Remove front propeller shaft at output flange of transfer case and tie to one side.

Scheme 18

1. Remove propeller shaft from transmission.
2. Release center bearing.
3. Tie propeller shaft to one side.

Tasks are described in 26 11 000 REMOVING AND INSTALLING PROPELLER SHAFT (CARDAN UNIVERSAL JOINT) COMPLETELY .

Note. Automatic transmission: Support transmission with special tools 00 2 030 / 24 5 301 / 24 5 305. Manual transmission: Support manual transmission with hydraulic lifter.

Scheme 19

Unfasten screws and remove transmission cross-member.

Tightening torque: 27 00 10AZ, see 27 00 TRANSFER BOX IN GENERAL .

Scheme 20

Detach plugs (1) and (2) from servomotor.

Scheme 21

Release screw connection of transfer case.

Tightening torque: 27 00 9AZ, see 27 00 TRANSFER BOX IN GENERAL .

Remove transfer case.

Installation

Pay attention to dowel pin (1).

Grease dowel pin (1).

Apply a thin coat of grease to splines.

Grease: WEICON ANTI-SEIZE.

Scheme 22

27 10 050 Replacing output flange for front axle output (ATC 400/500 X-Drive)

Operation is identical to Replacing radial shaft seal for front axle output, see 27 21 030 Replacing radial shaft seal for front axle output (ATC 400/500 X-Drive) .

27 10 700 Removing and installing / replacing control unit for transfer case

After installation

1. After replacement, the "Repair" service function must be carried out with GT1.
2. Replacement only: Carry out programming/coding

In vehicles before 03/05 the old diagnosis algorithm and in vehicles after 03/05 the new diagnosis algorithm must always be activated by way of coding!

Necessary preliminary tasks

1. Remove front panel for luggage compartment floor, see «51 47 131 REPLACING FRONT TRIM FOR LUGGAGE COMPARTMENT FLOOR»(ref-264509-S19688182702007091500000) .

Unscrew nuts (1).

Unfasten plug connection and disconnect.

Remove control unit (2).

Scheme 23

27 10 710 Replacing resistor for servomotor (ATC 400 X-Drive)

Release screws and remove transmission cross-member.

Tightening torque: 27 00 10AZ, see 27 00 TRANSFER BOX IN GENERAL .

Detach plug (1) from resistor.

Release screw (3) and remove resistor.

Tightening torque: 27 00 14AZ, see 27 00 TRANSFER BOX IN GENERAL .

27 10 720 Replacing servomotor (ATC 400 X-Drive)

Necessary preliminary tasks

1. Remove complete exhaust system, see «18 00 020 REMOVING AND INSTALLING COMPLETE EXHAUST SYSTEM (M54)»(ref-202780-S16724099112005102900000) .
2. Remove heat shield.

Release screws and remove transmission cross-member.

Tightening torque: 27 00 10AZ, see 27 00 TRANSFER BOX IN GENERAL .

Disconnect plugs (1 and 2).

Release screws and remove servomotor from transfer case.

Tightening torque: 27 00 13AZ, see 27 00 TRANSFER BOX IN GENERAL .

Scheme 24

27 21 010 Replacing radial shaft seal for drive flange (ATC 400/500 X-Drive)

Special tools required

1. «23 0 490 EXTRACTOR»(ref-265604-S41383564702007092300000)
2. «27 1 390 DRIFT»(ref-265608-S27125484352007092300000)

Necessary preliminary tasks

1. Remove transfer box, see «27 10 010 Removing and installing transfer case (ATC 400 X-Drive)»(ref-264500-S33211533842007091500000) .

Drive a hole into radial shaft seal (2) using a center punch (1).

Note. Illustration shows NV125 transmission

Scheme 25

Screw in special tool 23 0 490.

Drive out radial shaft seal (1) with impact weight (2).

Note. Illustration shows NV125 transmission

Scheme 26

Drive in radial shaft seal with special tool 27 1 390.

Scheme 27

Add final details to vehicle.

Check oil level.

Check transmission for leaks.

27 21 020 Replacing radial shaft seal for output flange (ATC 400/500 X-Drive)

Special tools required

1. «23 0 490 EXTRACTOR»(ref-265604-S41383564702007092300000)
2. «27 1 400 DRIFT»(ref-265608-S08163778872007092300000)
3. «33 1 150 FIXTURE»(ref-265611-S36804026112007092300000)

Necessary preliminary tasks

1. Remove transfer box, see «27 10 010 Removing and installing transfer case (ATC 400 X-Drive)»(ref-264500-S33211533842007091500000) .

Release retaining ring (1).

Scheme 28

Remove drive flange with special tool 33 1 150.

Scheme 29

Installation

Replace O-ring in output flange.

Check that O-ring is in correct position.

Scheme 30

Installation

Version: output shaft with mounting groove (1)

1. Push on output flange
2. Using 2 screwdrivers, press output flange downwards or output shaft (2) upwards until groove for retaining ring is completely visible.
3. Fit retaining ring.

Scheme 31

Installation

Version: transmission output shaft without mounting groove

1. Support transfer box with a suitable sleeve (1) on transmission input shaft (2).
2. Push on output flange
3. Fit retaining ring.

Scheme 32

Drive a hole into radial shaft seal (2) using a center punch (1).

See illustration.

Scheme 33

Screw in special tool 23 0 490.

Drive out radial shaft seal (1) with impact weight (2).

Scheme 34

Drive in radial shaft seal with special tool 27 1 400.

Scheme 35

Add final details to vehicle.

Check oil level.

Check transmission for leaks.

27 21 030 Replacing radial shaft seal for front axle output (ATC 400/500 X-Drive)

Special tools required

1. «23 0 490 EXTRACTOR»(ref-265604-S41383564702007092300000)
2. «27 1 410 DRIFT»(ref-265608-S38538043152007092300000)
3. 27 1 420

Necessary preliminary tasks

1. Remove reinforcement plate (E53 only), see «31 10 010 REMOVING AND INSTALLING/REPLACING REINFORCEMENT PLATE»(ref-264501-S19114980152007091500000) .
2. Remove front propeller shaft, see «REMOVAL & INSTALLATION»(ref-170165-S01786543362005010500000) .

Press out output flange (1) with a suitable tool (2) in direction of arrow.

Scheme 36

Remove protective cap (1) with a screwdriver.

Scheme 37

Drive a hole into radial shaft seal (2) using a center punch (1).

See illustration.

Note. Illustration shows E46 drive flange.

Screw in special tool 23 0 490.

Drive out radial shaft seal (1) with impact weight (2).

Note. Illustration shows E46 drive flange.

Drive in radial shaft seal with a suitable special tool.

Special tool for E53 27 1 420

Special tool for E83 27 1 410

Scheme 38

Add final details to vehicle.

Check oil level.

Check transmission for leaks.