27 10 010 Removing And Installing Transfer Case (ATC 300)

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2010 BMW 535xi, 2010 BMW 528xi, 2009 BMW 535xi, 2009 BMW 528xi, and 2008 BMW 535xi. However, it is still accessible from the selected car via links, so may be relevant.

Special tools required:

00 2 030. See MAINTENANCE AND GENERAL INFORMATION - SPECIAL TOOLS .
23 4 050. See MANUAL TRANSMISSION - SPECIAL TOOLS .

IMPORTANT: After replacement, the REPAIR service function must be carried out with GT1 (BMW scan tool).

IMPORTANT: After completing work, check gear oil level and top up if necessary.
Filler plug (1):
Tightening torque, 60 N.m.
Gear oil level up to filler edge of filler plug (1).
Use only the approved transmission fluid. See TRANSFER CASE - OPERATING FLUIDS .

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

Fig 1: Locating Oil Filler Plug

G04745099

Courtesy of BMW OF NORTH AMERICA, INC.

Necessary preliminary tasks:

Remove complete exhaust system. See EXHAUST SYSTEM - REPAIR INSTRUCTIONS .
Remove underbody protection
Remove heat shields

Release screws.

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

Installation:

Replace screws.

Fig 2: Identifying Front Propeller Shaft Screws

G04745103

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 removing propeller shaft. See 26 11 000 REMOVING AND INSTALLING COMPLETE PROPELLER SHAFT (CONSTANT-VELOCITY JOINT) .

NOTE: Support transmission with special tool 00 2 030/23 4 050.

Fig 3: Identifying Special Tool (00 2 030) And (23 4 050)

G04745104

Courtesy of BMW OF NORTH AMERICA, INC.

If necessary

Release bolts and remove metal plate (1).

Fig 4: Identifying Metal Plate

G04745105

Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 5: Identifying Plugs And Servomotor

G04745106

Courtesy of BMW OF NORTH AMERICA, INC.

Release screws.

Remove transmission crossmember.

Tightening torque, 19 N.m.

Fig 6: Identifying Transmission Crossmember Screws

G04745107

Courtesy of BMW OF NORTH AMERICA, INC.

Release screw connection of transfer case.

Tightening torque, 43 N.m.

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 7: Identifying Dowel Pin

G04745108

Courtesy of BMW OF NORTH AMERICA, INC.