Transfer Case - Removal & Installation BMW X5 E53

TRANSFER BOX (ATC 500 X-DRIVE TRANSFER BOX)

Note. Numbers in text refer to numbers in figures.

Note. After completing work, check gear oil level and top up if necessary. Tighten filler plug (1) as necessary. See TORQUE SPECIFICATIONS. Fill gear oil level up to filler edge of filler plug (1). (Scheme 1) Use only the approved gear oil. See TRANSFER CASE - SERVICING article.

Scheme 1

On 4.4L, remove catalytic converter. See EXHAUST SYSTEM . On all models, remove front and rear heat shields.

Grip clamping sleeve (1) and slacken nut (2). Pull out retainer (3) using a screwdriver. (Scheme 2) NOTE: During installation, adjust selector lever. See ADJUSTING SELECTOR LEVER.

Scheme 2

Remove propeller shaft from transmission. Release center bearing. Tie propeller shaft to one side. Support automatic transmission with hydraulic lifter. Unfasten screws and remove transmission crossmember (1). (Scheme 3)

Scheme 3

Detach plugs (1) and (2) from servomotor. (Scheme 4)

Scheme 4

Release screw connection of transfer case. Remove transfer case. During installation, pay attention to dowel pin (1). Grease dowel pin (1). (Scheme 5) Apply a thin coat of Weicon anti-seize grease to splines.

Scheme 5

TRANSFER CASE (A/T)

Note. Numbers in text refer to numbers in figures.

Note. After completing work, check gear oil level and top up if necessary. Tighten filler plug (1) as necessary. See TORQUE SPECIFICATIONS. Fill gear oil level up to filler edge of filler plug (1). (Scheme 1) See TRANSFER CASE - SERVICING article.

Move selector lever to park position "P". Remove exhaust system. See EXHAUST SYSTEM. Remove bolts (1) and (2) and remove reinforcement plate. (Scheme 6) Do not drive vehicle while reinforcement plate is removed.

Scheme 6

Remove heat shields. Unclip cables for oxygen sensors. Release stabilizer bar. See STABILIZER BAR .

Remove heat shield at rear. (Scheme 7) Remove front propeller shaft. See FRONT PROPELLER SHAFT.

Scheme 7

Grip clamp bushing (1) and slacken nut (2). (Scheme 8)

Scheme 8

During installation, adjust selector lever. See ADJUSTING SELECTOR LEVER. Grip cable (1) at hexagon (2). Release nut (3). Pull cable (1) out of holder. (Scheme 9)

Scheme 9

On automatic transmission (A5S 440Z-5HP24), support transmission with special tool (00 2 030/24 5 301/24 0 250). (Scheme 10)

Scheme 10

On automatic transmission A5S 360R-GM5, support transmission with special tools (00 2 030/24 5 301/24 5 305). (Scheme 11)

Scheme 11

Unclip oxygen sensor cable at transmission crossmember. Release screws and remove transmission crossmember. (Scheme 12)

Scheme 12

Detach vent line (1). Unclip oxygen sensor cable at transfer case. (Scheme 13)

Scheme 13

Release bolts. (Scheme 14) During installation, replace self-locking nuts. Only tighten screw connection by way of nut. This prevents the flexible disk from being subjected to torsion stress.

Scheme 14

Grip propeller shaft at center mount and release nuts. (Scheme 15)

Scheme 15

During installation, center mount must be aligned at right angles to propeller shaft. DO NOT let propeller shaft fall into joints as joints and rubber sleeve can be damaged on constant-velocity joint. (Scheme 16)

Scheme 16

Bend propeller shaft downward at center mount. (Scheme 17)

Scheme 17

Remove propeller shaft from transmission output flange and tie back to one side with cord or wire. Take up transfer case (1) with special tools (27 1 100). (Scheme 18)

Scheme 18

Release transfer case screw connection on transmission. Remove transfer case. During installation, pay attention to dowel sleeves. (Scheme 19) Replace damaged dowel sleeves. Apply a thin coat of Weicon antisize grease to splines.

Scheme 19

TRANSFER CASE (M/T)

Note. Numbers in text refer to numbers in figures.

Note. After completing work, check gear oil level and top up if necessary. Tighten filler plug (1) as necessary. See TORQUE SPECIFICATIONS. Fill gear oil level up to filler edge of filler plug (1). (Scheme 1) Use only the approved gear oil. See TRANSFER CASE - SERVICING article.

Remove exhaust system. See EXHAUST SYSTEM. Remove heat shield at rear. Remove bolts (1, 2) and remove reinforcement plate. (Scheme 6) Do not drive vehicle while reinforcement plate is removed. Release stabilizer bar. See STABILIZER BAR. Remove front propeller shaft. See FRONT PROPELLER SHAFT.

On manual transmission (S5D 280Z), support transmission with special tools (00 2 030 and 23 0 130). (Scheme 20)

Scheme 20

Release screws and remove transmission crossmember. (Scheme 12)

Detach vent line (1). Unclip cable from transfer case. (Scheme 13)

Release screws. During installation, replace self-locking nuts. When tightening screws down, grip each screw and tighten down nut. This prevents the flexible disk from being subjected to torsion stress. (Scheme 14)

Grip propeller shaft at center mount and release nuts. During installation, center mount must be aligned at right angles to propeller shaft. (Scheme 15) DO NOT let propeller shaft fall into joints. (Scheme 16) Joints and rubber sleeve can be damaged on constant-velocity joint.

Bend propeller shaft downwards at center mount, remove from transmission output flange and tie back to one side with cord or wire. (Scheme 17)

Take up transfer case with special tools (27 1 100 and 00 2 030). Release transfer case screw connection on transmission. Remove transfer case. (Scheme 18)

During installation, note dowel sleeves. (Scheme 19) Replace damaged dowel sleeves. Apply a thin coat of Weicon antisize grease to splines. Replace sealing ring (1) on drive shaft (2) of transfer case. (Scheme 21)

Scheme 21

TRANSFER BOX REPLACEMENT (ATC 500 X-DRIVE TRANSFER BOX)

Note. Numbers in text refer to numbers in figures.

Note. When replacing the transfer box, it is important to delete the self adapting wear values (oil, clutch) in the transfer box control unit. After completing work, check transmission fluid level and top up if necessary. Fluid level should be to lower edge of filler plug (1). (Scheme 1) Use only the approved gear oil. See TRANSFER CASE - SERVICING article.

Installation Of Replacement Transfer Case

Note location of filler plug (1) and drain transfer case oil. Remove old transfer box. See TRANSFER BOX (ATC 500 X-DRIVE TRANSFER BOX). On manual transmission, remove screws and convert vibration damper. (Scheme 22) On all models, swap covers and protective caps, drive shaft transportation lock, vent hose of transfer box, and rubber mount for transfer case mounting.

Scheme 22

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• TRANSFER CASE - SERVICING
• TORQUE SPECIFICATIONS
• TRANSFER BOX (ATC 500 X-DRIVE TRANSFER BOX)