27 10 070 Replacing Output Flange On Transfer Case At Rear (ATC300)

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.

IMPORTANT: After completing work, check gear oil level and top up if necessary.
Use only the approved gear oil in this transfer case. See TRANSFER CASE - OPERATING FLUIDS .

NOTE:

Operations for removing output flange are identical to replacing radial shaft seal (M/T) or 27 21 020 REPLACING RADIAL SHAFT SEAL FOR OUTPUT FLANGE, AUTOMATIC (ATC 300)

Installation:

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

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

Fig 1: Identifying Output Flange Dimension

Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 2: Identifying Output Flange Dimension

Courtesy of BMW OF NORTH AMERICA, INC.

Determine measurement C, thickness of shim.

Fig 3: Identifying Shim Thickness

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

Calculate thickness of new shim:

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