Transfer Box - Repair BMW X5 E70

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 ... Replenishing /Changing Transfer Case Oil (ATC 700)

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

Necessary preliminary tasks

1. Remove underbody protection. See «51 47 491 REMOVING AND INSTALLING/REPLACING REAR UNDERBODY PROTECTION»(/bmw/x5/e70-2006-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-47-491-removing-and-installingreplacing)
2. If necessary, remove exhaust system
3. Remove heat shields

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 TRANSFER BOX IN GENERAL .

Replace sealing ring.

Scheme 1

Changing transfer case oil

Place oil collecting apparatus underneath.

Remove oil drain plug (1).

Drain and dispose of gear oil.

Note. Observe country-specific waste-disposal regulations Replace sealing ring, screw in oil drain plug (1) and tighten down.

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

Scheme 2

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 TRANSFER BOX IN GENERAL .

Replace sealing ring.

27 00 ... Replenishing / changing transfer box oil (ATC 450)

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

Necessary preliminary tasks

1. Remove transmission cross-member.

Check transfer box oil level, correct

Undo oil filler plug (1).

Check transfer box oil level.

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

Scheme 3

Installation note: Tightening torque 27 00 11AZ.

Replace oil filler plug (1).

Changing transfer box oil

Remove exhaust system holder from transmission.

Tightening torque 18 20 1AZ.

Place oil collecting apparatus underneath

Remove oil drain plug (1).

Scheme 4

Drain and dispose of transmission oil.

Note. Observe country-specific waste disposal regulations

Installation note: Replace oil drain plug (1).

Tightening torque 27 00 11AZ.

Undo oil filler plug (1).

Scheme 5

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

Tightening torque 27 00 11AZ.

Replace oil filler plug (1).

27 10 010 Removing and Installing Transfer Box ATC 700 (Automatic Transmission)

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

Necessary preliminary tasks

1. Remove underbody protection. See «51 47 491 REMOVING AND INSTALLING/REPLACING REAR UNDERBODY PROTECTION»(/bmw/x5/e70-2006-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-47-491-removing-and-installingreplacing)
2. Remove exhaust system bracket from transmission and transfer box
3. Remove front and rear heat shields
4. Support transmission. See «23 .. UNIVERSAL TRANSMISSION BRACKET»(/bmw/x5/e70-2006-2010/remont/automatic-trans/#automatic-transmission-repair__23-universal-transmission-bracket)
5. Remove propeller shaft. See «26 11 000 REMOVING AND INSTALLING PROPELLER SHAFT (INSERTED) COMPLETELY»(/bmw/x5/e70-2006-2010/remont/driveshaft-universal-joints/#propeller-shaft-repair)
6. Remove front propeller shaft.
7. Remove transmission cross-member. See «22 32 050 REPLACING CROSS-MEMBER FOR TRANSMISSION MOUNTING»(/bmw/x5/e70-2006-2010/remont/mechanical/#engine-and-gearbox-suspension-repair-n52__22-32-050-replacing-cross-member-for)

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

Scheme 6

Release screw connection of transfer case.

Tightening torque 27 00 9AZ, see 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 7

27 10 020 Installing distributor exchange transmission (ATC 450)

Catch and dispose of escaping transmission oil. Observe country-specific waste disposal regulations

Necessary preliminary tasks

1. Drain «transmission oil at oil drain plug»(/bmw/x5/e70-2006-2010/remont/transfer-case/#transfer-box-repair__27-00-replenishing-changing) .
2. Tightening torque, see 27 00 11AZ in «27 00 TRANSFER BOX IN GENERAL»(/bmw/x5/e70-2006-2010/remont/transfer-case/#transfer-box-tightening-torques__27-00-transfer-box-in-general) .
3. Remove transfer box.

Modify following parts

1. Covers and protective caps.
2. Drive shaft transportation retainer.
3. Vent hose of transfer box.

Release filler plug (1). Check oil level. Tightening torque, see 27 00 11AZ in 27 00 TRANSFER BOX IN GENERAL . Pour in transmission oil up to lower edge of opening for filler plug (1). Use only the approved transmission oil.

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

27 10 020 Installing Replacement Transfer Box (ATC 700)

Recycling

Catch and dispose of escaping transmission fluid. Observe country-specific waste-disposal regulations.

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

Necessary preliminary tasks

1. Drain transmission oil at oil drain plug Tightening torque, 27 00 11AZ, see «TRANSFER BOX IN GENERAL»(/bmw/x5/e70-2006-2010/remont/transfer-case/#transfer-box-tightening-torques__27-00-transfer-box-in-general) .
2. Remove transfer box. See «27 10 010 Removing and Installing Transfer Box ATC 700 (Automatic Transmission)»(/bmw/x5/e70-2006-2010/remont/transfer-case/#transfer-box-repair__27-10-010-removing-and-installing)

Modify following parts

1. Covers and protective caps
2. Drive shaft transportation lock
3. Vent hose of transfer box

27 10 020 Installing replacement transfer box (ATC 350)

Special tools required

1. 22 1 044
2. 22 1 046
3. «33 4 460»(/bmw/x5/e70-2006-2010/remont/axle-shafts/#rear-axle-special-tools)

Catch and dispose of escaping transmission oil. Observe country-specific waste disposal regulations

Necessary preliminary work

1. Drain transmission oil at oil drain plug.
2. Tightening torque, see 27 10 2AZ in «27 00 TRANSFER BOX IN GENERAL»(/bmw/x5/e70-2006-2010/remont/transfer-case/#transfer-box-tightening-torques__27-00-transfer-box-in-general) .
3. Remove transfer box.

Modify following parts

1. Covers and protective caps.
2. Drive shaft transportation retainer.
3. Vent hose of transfer box.

Bolt special tool 22 1 044 to transfer box. Insert special tool 22 1 046 with pins into opening of rubber mount. Draw in rubber mount with special tool 33 4 460 .

Scheme 8

Installation note: Pay attention to installation position of rubber mount (1).

Scheme 9

Release filler plug (1). Check oil level. Tightening torque, see 27 10 2AZ in TRANSFER BOX IN GENERAL . Pour in transmission oil up to lower edge of opening for filler plug (1). Use only the approved transmission oil. See TRANSFER CASE - OPERATING FLUIDS .

Scheme 10

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

27 10 050 Replacing output flange for front axle output (ATC 450)

Operation is identical to Replacing radial shaft seal for front axle output .

27 10 070 Replacing Output Flange on Transfer Box at Rear (ATC 700)

Note. Operations for removing output flange are identical to replacing radial shaft seal. See 27 21 020 Replacing Radial Shaft Seal for Output Flange (ATC 700) .

Installation

1. Thickness of new shim must be determined before output flange is installed

Determine and note down measurement A of output flange (previous and new).

Scheme 11

Determine and note down measurement B of output flange (previous and new).

Scheme 12

Determine measurement C, thickness of shim.

Scheme 13

Installation

Calculate thickness of new shim

1. Add measurement A of output flange (previous) and measurement C of shim (previous) Then subtract measurement B (previous) from result A+C (previous)
2. Subtract measurement B from measurement A of output flange (new)
3. Then subtract result of step 2 from result of step 1 .

27 10 070 Replacing output flange on transfer box at rear (ATC450)

Note. Replace output flange only together with a new radial shaft seal. Operations for removing output flange are identical to replacing radial shaft seal.

Note. Thickness of new shim must be determined before output flange is installed.

Determine and note down dimension A of output flange (previous and new).

Scheme 14

Determine and note down dimension B of output flange (previous and new).

Scheme 15

Determine dimension C, thickness of shim.

Scheme 16

Note. Add dimension A of output flange (previous) and dimension C of shim (previous). Then subtract dimension B (previous) from result A+C (previous). Subtract dimension B from dimension A of output flange (new). Then subtract result of step 2 from result of step 1.

27 10 700 Removing and Installing / Replacing Control Unit for Transfer Box (ATC 700)

1. Replacement: Before and after replacement, execute the "Repair" service function with the BMW diagnosis system.

Necessary preliminary tasks

1. Raise luggage compartment floor trim

Release screws (1).

Remove battery cover (2) towards top.

Scheme 17

Disconnect connector (1).

Unscrew nuts.

Remove control unit.

Scheme 18

27 10 710 Replacing Classification Resistor for Servomotor (ATC 700)

Disconnect connector (1).

Release screw (2) and remove resistor.

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

Scheme 19

27 10 710 Replacing classification resistor for control motor S63 (ATC 700)

Necessary preliminary tasks

1. Remove exhaust system. See «EXHAUST - REPAIR - X5 (6 CYL)»(/bmw/x5/e70-2006-2010/remont/exhaust/#exhaust-repair-n52) or «EXHAUST - REPAIR - X5 (V8)»(/bmw/x5/e70-2006-2010/remont/exhaust/#exhaust-repair-n62) .
2. Remove heat shield

Disconnect connector (1). Release screw (2) and remove resistor. Tightening torque 27 00 14AZ, see TRANSFER BOX IN GENERAL .

27 10 720 Replacing Servomotor (ATC 700)

Disconnect plugs (1 and 2).

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

Release screws and remove servomotor from transfer box.

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

Scheme 20

27 10 730 Replacing VTG control unit (longitudinal torque module) (ATC 450)

Special tools required

1. 11 1 200
2. 11 1 380
3. 23 0 490

Necessary preliminary work

1. Disconnect battery earth lead. See «12 00... INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY»(/bmw/x5/e70-2006-2010/remont/horns/#general-electrical-system-repair__12-00-instructions-for-disconnecting-and) .
2. Remove cross member.

Disconnect connector (1). Release screws (2) and remove transfer box from control unit (longitudinal torque module) (3). Tightening torque, see 27 00 13AZ in TRANSFER BOX IN GENERAL .

Scheme 21

Note. Radial shaft seal of actuator shaft must be replaced as well.

Thread special tool 23 0 490 into radial shaft seal (1). Drive out radial shaft seal (1) with impact weight (2).

Scheme 22

Push the assembly sleeve 11 1 380 over the actuator shaft.

Scheme 23

Slide the new radial shaft seal (1) over the assembly sleeve (2) onto the actuator shaft.

Scheme 24

Drive radial shaft seal fully home using special tool 11 1 200 and plastic hammer. Remove the assembly sleeve.

Scheme 25

27 21 010 Replacing Radial Shaft Seal for Drive Flange (ATC 700)

Special tools required

1. 23 0 490
2. 27 1 460 «DRIFT»(/bmw/x5/e70-2006-2010/remont/transfer-case/#transfer-box-special-tools)

Necessary preliminary tasks

1. Remove transfer box, see «27 10 010 Removing and Installing Transfer Box ATC 700 (Automatic Transmission)»(/bmw/x5/e70-2006-2010/remont/transfer-case/#transfer-box-repair__27-10-010-removing-and-installing)

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

Scheme 26

Screw in special tool 23 0 490 .

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

Scheme 27

Drive in radial shaft seal with special tool 27 1 460, see DRIFT .

Scheme 28

Add final details to vehicle.

Check oil level.

Check transmission for leaks.

27 21 020 Replacing Radial Shaft Seal for Output Flange (ATC 700)

Special tools required

1. 23 0 490
2. 27 1 480, see «DRIFT»(/bmw/x5/e70-2006-2010/remont/transfer-case/#transfer-box-special-tools)

Necessary preliminary tasks

1. Remove underbody protection. See «51 47 491 REMOVING AND INSTALLING/REPLACING REAR UNDERBODY PROTECTION»(/bmw/x5/e70-2006-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-47-491-removing-and-installingreplacing)
2. Support transmission. See «23 .. UNIVERSAL TRANSMISSION BRACKET»(/bmw/x5/e70-2006-2010/remont/automatic-trans/#automatic-transmission-repair__23-universal-transmission-bracket)
3. Release exhaust system bracket
4. Remove propeller shaft. See «26 11 000 REMOVING AND INSTALLING PROPELLER SHAFT (INSERTED) COMPLETELY»(/bmw/x5/e70-2006-2010/remont/driveshaft-universal-joints/#propeller-shaft-repair)
5. Remove transmission cross-member. See «22 32 050 REPLACING CROSS-MEMBER FOR TRANSMISSION MOUNTING»(/bmw/x5/e70-2006-2010/remont/mechanical/#engine-and-gearbox-suspension-repair-n52__22-32-050-replacing-cross-member-for)

Release retaining ring (1).

Scheme 29

Installation

Replace O-ring in output flange.

Check that O-ring is in correct position.

Scheme 30

Installation

Scheme 31

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.

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

Scheme 32

Screw in special tool 23 0 490 .

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

Scheme 33

Drive in radial shaft seal with special tool 27 1 480 DRIFT .

Scheme 34

Add final details to vehicle.

Check oil level.

Check transmission for leaks.

27 21 020 Replacing radial shaft seal for output flange (ATC 450)

Special tools required

1. 27 1 440

Necessary preliminary tasks

1. Remove propeller shaft. See «26 11 000 REMOVING AND INSTALLING PROPELLER SHAFT (INSERTED) COMPLETELY»(/bmw/x5/e70-2006-2010/remont/driveshaft-universal-joints/#propeller-shaft-repair) .

Release circlip (1).

Scheme 35

Release output flange with three-claw extractor tool. Lever radial shaft seal out of housing with a suitable tool

Scheme 36

Installation note: Replace O-ring in output flange. Check that O-ring is in correct position.

Scheme 37

Installation note: Coat sealing lips of new radial shaft seal with clean transmission oil. Drive in radial shaft seal with special tool 27 1 440.

Scheme 38

Scheme 39

27 21 030 Replacing Radial Shaft Seal for Front Axle Output (ATC 700)

Special tools required

1. 23 0 490
2. 27 1 470 «DRIFT»(/bmw/x5/e70-2006-2010/remont/transfer-case/#transfer-box-special-tools)

Necessary preliminary tasks

1. Remove front propeller shaft. See «26 20 000 REMOVING AND INSTALLING FRONT PROPELLER SHAFT (N52K, M57T2, N54, N55, N57)»(/bmw/x5/e70-2006-2010/remont/driveshaft-universal-joints/#propeller-shaft-repair__26-20-000-removing-and-installing) .

Remove protective cap (1) with a screwdriver.

Scheme 40

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

Scheme 41

Screw in special tool 23 0 490.

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

Scheme 42

Drive in radial shaft seal with special tool 27 1 470 DRIFT .

Scheme 43

Add final details to vehicle.

Check oil level.

Check transmission for leaks.

27 21 030 Replacing radial shaft seal for front axle output (ATC 450)

Special tools required

1. 23 0 490
2. «27 1 470»(/bmw/x5/e70-2006-2010/remont/transfer-case/#transfer-box-special-tools)

Necessary preliminary tasks

1. Remove front propeller shaft. See «26 20 000 REMOVING AND INSTALLING FRONT PROPELLER SHAFT (N52K, M57T2, N54, N55, N57)»(/bmw/x5/e70-2006-2010/remont/driveshaft-universal-joints/#propeller-shaft-repair__26-20-000-removing-and-installing) .

Remove protective cap (1) with a screwdriver.

Scheme 44

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

Scheme 45

Screw in special tool 23 0 490. Drive out radial shaft seal (1) with impact weight (2).

Scheme 46

Drive in radial shaft seal with special tool 27 1 470.

Scheme 47

Reassemble the vehicle. Check oil level. Check transmission for leaks.

27 21 040 Replacing radial shaft seal for actuator shaft (ATC 450)

Special tools required

1. 11 1 200
2. 11 1 380
3. 23 0 490

Necessary preliminary tasks

1. Disconnect battery earth lead. See «12 00... INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY»(/bmw/x5/e70-2006-2010/remont/horns/#general-electrical-system-repair__12-00-instructions-for-disconnecting-and) .
2. Remove cross member.

Disconnect connector (1). Release screws (2) and remove transfer box from control unit (longitudinal torque module) (3). Tightening torque, see 27 00 13AZ in TRANSFER BOX IN GENERAL .

Scheme 48

Screw special tool 23 0 490 into radial shaft seal. Drive out radial shaft seal (1) with impact weight (2).

Scheme 49

Push the assembly sleeve 11 1 380 over the actuator shaft.

Scheme 50

Slide the new radial shaft seal (1) over the assembly sleeve (2) onto the actuator shaft.

Scheme 51

Drive radial shaft seal fully home using special tool 11 1 200 and plastic hammer. Remove the assembly sleeve.

Scheme 52

See also:
• 00 DANGER OF POISONING IF OIL IS INGESTED/ABSORBED THROUGH THE SKIN
• 00 RISK OF INJURY IF OIL COMES INTO CONTACT WITH EYES AND SKIN
• 51 47 491 REMOVING AND INSTALLING/REPLACING REAR UNDERBODY PROTECTION
• TRANSFER BOX IN GENERAL
• 51 71 505 MOUNT SECURING FIXTURE FOR VEHICLE ON LIFTING PLATFORM
• 23 .. UNIVERSAL TRANSMISSION BRACKET
• 26 11 000 REMOVING AND INSTALLING PROPELLER SHAFT (INSERTED) COMPLETELY
• 22 32 050 REPLACING CROSS-MEMBER FOR TRANSMISSION MOUNTING
• 33 4 460
• TRANSFER CASE - OPERATING FLUIDS
• 61 35... NOTES ON ESD PROTECTION (ELECTRO STATIC DISCHARGE)
• EXHAUST - REPAIR - X5 (6 CYL)
• EXHAUST - REPAIR - X5 (V8)
• 12 00... INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY
• DRIFT
• 26 20 000 REMOVING AND INSTALLING FRONT PROPELLER SHAFT (N52K, M57T2, N54, N55, N57)
• transmission oil at oil drain plug
• 27 10 010 Removing and Installing Transfer Box ATC 700 (Automatic Transmission)
• Replacing radial shaft seal for front axle output
• 27 21 020 Replacing Radial Shaft Seal for Output Flange (ATC 700)
• 27 00 ... Replenishing /Changing Transfer Case Oil (ATC 700)
• 27 10 070 Replacing Output Flange on Transfer Box at Rear (ATC700)