replacing the exchange transfer box

Preliminary work 

• Deactivate the 48 v ELECTRICAL SYSTEM .
• Disconnect all battery GROUND LEADS .
• Remove rear UNDERBODY PROTECTION .
• Remove the transmission side UNDERBODY PLANKING
• Remove the tunnel connecting SUPPORT .
• If installed: remove the right and left TORSION STRUT where required.
• Remove the HEAT SHIELDS .
• Remove transmission CROSS-MEMBER .
• Remove the RETAINING PLATES
• Partially loosen the PROP SHAFT
• Remove the TRANSFER BOX  (ATC 13-1).

Install the transfer box (ATC 13-1) 

• Apply a thin layer of grease to the gearing (1) in the transfer box (VTG) and the gearing (2) on the automatic transmission.
  CONSUMABLE - BALL BEARING GREASE DESCRIPTION
  
  

  Ball bearing grease

  100 g, Tube

  81229407174

  Courtesy of BMW OF NORTH AMERICA, INC.

• Replace the O-ring (1) before installing the front prop shaft in the transfer box (VTG).

  Parts:  O-ring

• Apply a thin coat of grease to the gearing of the output flange in the transfer box (VTG).
  CONSUMABLE - BALL BEARING GREASE DESCRIPTION
  
  

  Ball bearing grease

  100 g, Tube

  81229407174

  Courtesy of BMW OF NORTH AMERICA, INC.

• Position the transfer box (VTG) with the help of a support person.
• Position the front prop shaft (1) on the output flange (3) of the transfer box (VTG).
• Align the front prop shaft (1) with markings (2) and (4).
• Install the transfer box (VTG) and at the same time slide the front prop shaft (1) into the output flange (3) of the transfer box (VTG).
• Remove any leaked grease on the prop shaft.

  Courtesy of BMW OF NORTH AMERICA, INC.

  NOTE: TECHNICAL INFORMATION 
  When assembling, it is essential to observe screwing sequences and tightening torques.
  Failure to comply with the regulations can lead to leaks and damage.
• Tighten screws in the order (1) to (5).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Transfer box to automatic transmission
  M10	Tightening torque	43 Nm

  Courtesy of BMW OF NORTH AMERICA, INC.

• Connect the connector (1) on the VTG control unit (longitudinal torque distribution) (2).

  Courtesy of BMW OF NORTH AMERICA, INC.

• Install the ground strap (2).
• Tighten down screw (1).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Ground strap to transmission or body
  M8	Tightening torque	19 Nm

  Courtesy of BMW OF NORTH AMERICA, INC.

  Change transfer box oil (ATC 13-1) 

• Open the oil filler plug (1).

  Courtesy of BMW OF NORTH AMERICA, INC.

  NOTE: TECHNICAL INFORMATION 
  Collect and dispose of emerging fluids.

  Observe country-specific waste disposal regulations.

• Extract the transmission oil from the transfer box (VTG) using special tool 0 493 337 (00 2 080)  and special tool 2 457 963. 

  Courtesy of BMW OF NORTH AMERICA, INC.

• Top up transmission oil up to the lower edge of the opening for the oil filler plug using special tool 0 493 337 (00 2 080)  .
  TECHNICAL DATA - TRANSFER BOX SPECIFICATION
  
  

  Filling capacity of transfer box
  Transfer-box oil	min. 0.7 L

  Courtesy of BMW OF NORTH AMERICA, INC.

• Replace the oil filler plug (1).

  Parts:  Oil filler plug

• Tighten the oil filler plug (1).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Oil filler and oil drain plugs
  M22	Tightening torque	60 Nm

  Courtesy of BMW OF NORTH AMERICA, INC.

• Remount covers and protective caps.
• Remove transportation retainer of the transmission input shaft.
• Remount the vent hose from the transfer box.
• Make note of transmission identification (see BMW Group parts sales and nameplate).

ENCODE/PROGRAM  control unit(s) 

Prerequisite 

The control unit was replaced.

• Connect the battery charger to the vehicle (activity not included in the flat rate unit).
• Connect the programing system with the vehicle.
• Determine the action plan.
• Accept and fully process the action plan.
• Depending on the reworking list, connect the workshop system to the vehicle if necessary.
• Carry out vehicle test.
• Delete the fault memory.
• Note the information on programing in the workshop system and the relevant information in the user documentation.
• Wait until programing/coding has been completed.
• Disconnect the programing system from the vehicle.
• Disconnect the battery charger from the vehicle.

Follow-up work 

• Install the transmission bearing RUBBER MOUNT (all-wheel drive).
• Fasten the (partially removed) PROP SHAFT
• Install transmission CROSS MEMBER .
• Reconnect all battery GROUND LEADS .
• Check/top up the transfer box OIL (active torque control 13-1).
• Install the RETAINING PLATES .
• Install the HEAT SHIELDS .
• If installed: install the right and left TORSION STRUT where required.
• Install the tunnel connecting SUPPORTS .
• Install the transmission side UNDERBODY PLANKING .
• Install rear UNDERBODY PROTECTION .
• Install the luggage compartment FLOOR COVERING .
• Activate the 48 v ELECTRICAL SYSTEM .