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

WARNING: This page is about a different car, the 2010 BMW X3, 2009 BMW X3, 2008 BMW X3, and 2007 BMW X3. However, it is still accessible from the selected car via links, so may be relevant.

Special tools required:

00 2 030
24 5 301
24 5 305

IMPORTANT: After replacement, the "Repair" service function must be carried out with GT1.

IMPORTANT: After completing work, check gear oil level and top up if necessary.
Filler plug (1):
Tightening torque: 27 00 11AZ, see 27 00 TRANSFER BOX IN GENERAL .
Gear oil level up to filler edge of filler plug (1).
Use only the approved gear oil.

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

Fig 1: Oil Filler Plug And Oil Drain Plug

G04786855

Courtesy of BMW OF NORTH AMERICA, INC.

Necessary preliminary tasks:

Remove complete exhaust system, see 18 00 020 REMOVING AND INSTALLING COMPLETE EXHAUST SYSTEM .
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.

Fig 2: Front Propeller Flange Shaft Screws

G04787523

Courtesy of BMW OF NORTH AMERICA, INC.

Remove propeller shaft from transmission.
Release center bearing.
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.

Fig 3: Special Tools (00 2 030), (24 5 301) And (24 5 305)

G04787524

Courtesy of BMW OF NORTH AMERICA, INC.

Unfasten screws and remove transmission cross-member.

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

Fig 4: Transmission Cross-Member Screws

G04787359

Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 5: Plugs And Servomotor

G04787526

Courtesy of BMW OF NORTH AMERICA, INC.

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.

Fig 6: Dowel Pin

G04787527

Courtesy of BMW OF NORTH AMERICA, INC.