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      04-19-2016, 10:32 AM   #1
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2012 x5 transfer case replacement help.

Hey guys, after 105k miles my transfer case seems to be on the way out as at tight turns I'm getting some shuttering, it also seems to have been an issue on the 2012 model year that resulted in a redesign later.

Is their any DIY's out their that show how to do the swap? It doesn't seem like I need to lower the subframe or anything. Just wondering how bad of a job it is to do myself.

Thanks!
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      04-20-2016, 08:26 AM   #2
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I have no DIY suggestions, but if it ends up being outside your comfort zone, check out Bimmer Werkshop in Chicago on Montrose. Former Perillo techs, all work done for 1/2 of dealership costs using OEM parts. They are true enthusiasts.
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      04-20-2016, 09:46 AM   #3
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Quote:
Originally Posted by Poppyboy
I have no DIY suggestions, but if it ends up being outside your comfort zone, check out Bimmer Werkshop in Chicago on Montrose. Former Perillo techs, all work done for 1/2 of dealership costs using OEM parts. They are true enthusiasts.
Awesome ! Thanks !
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      06-23-2016, 03:27 PM   #4
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My friend , no need to change transfer case, all you have to do is to change small gear inside the transfer case , it's plastic part and it will not cost you more than 20$
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      06-23-2016, 03:41 PM   #5
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Quote:
Originally Posted by bmw745 View Post
My friend , no need to change transfer case, all you have to do is to change small gear inside the transfer case , it's plastic part and it will not cost you more than 20$
Not sure how close the AWD setup is compared to the E53, but on my previous vehicle (2006 4.8iS) I had the motor slipping that actuated the AWD system. Warning lights (ABS, DTC, 4x4) every time I put it in gear.

I could have replaced the plastic gear for cheap...hell, even the motor itself...but I decided to just spin the worn side of that plastic gear and put it back on (seems only one side of the plastic gear is used) to try it out first...no issues for another 20K miles until I traded it...
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      06-23-2016, 05:30 PM   #6
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So is it hard to replace ? Dealer tells me it was the clutches slipping in the transfercase

What's the part number ? Or where can I buy it ?
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      06-23-2016, 05:52 PM   #7
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Quote:
Originally Posted by -c- View Post
So is it hard to replace ? Dealer tells me it was the clutches slipping in the transfercase

What's the part number ? Or where can I buy it ?
My dealer told me the same thing last week. My issue was solved with a software/ilevel update. What are your symptoms? EDIT, Just noticed symptoms in the first post. If you feel it in tight turns, then it is the clutches. Have you changed your fluid yet? $40 for a quart is worth the risk.

If indeed you need a TC, reach out to these people for parts. I have not found a repair manual but the repair does not look that difficult. http://www.ebay.com/itm/ATC500-700-T...8AAOSwfZ1WZb2f
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      06-23-2016, 06:00 PM   #8
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Quote:
Originally Posted by smassey321
Quote:
Originally Posted by -c- View Post
So is it hard to replace ? Dealer tells me it was the clutches slipping in the transfercase

What's the part number ? Or where can I buy it ?
My dealer told me the same thing last week. My issue was solved with a software/ilevel update. What are your symptoms? EDIT, Just noticed symptoms in the first post. If you feel it in tight turns, then it is the clutches. Have you changed your fluid yet? $40 for a quart is worth the risk.

If indeed you need a TC, reach out to these people for parts. I have not found a repair manual but the repair does not look that difficult. http://www.ebay.com/itm/ATC500-700-T...8AAOSwfZ1WZb2f
Yea it feels fine in a straight line and only tight turns and turning In reverse the transfer case shutters, changed the fluid and it helped immensely for a while but I know the case itself went through 4 design changes in the course of a couple years so the newest design is the best.

May just change the whole thing, these rebuild kits when all said and done are almost the same price.

Thanks for the info. Mines a 2012 model year.
Seems hard to find a good transfer case for this model year.
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      06-25-2016, 08:41 AM   #9
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Quote:
Originally Posted by -c- View Post
Yea it feels fine in a straight line and only tight turns and turning In reverse the transfer case shutters, changed the fluid and it helped immensely for a while but I know the case itself went through 4 design changes in the course of a couple years so the newest design is the best.

May just change the whole thing, these rebuild kits when all said and done are almost the same price.

Thanks for the info. Mines a 2012 model year.
Seems hard to find a good transfer case for this model year.
Wasn't hard at all, would just have to make a ton of room underneath the vehicle to get to it..

However, our symptoms sound nothing alike, your dealer might be spot on, on this one...sorry I couldn't be of more help...
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      07-04-2016, 03:11 AM   #10
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They replaced mine under warranty with 21,500 miles back in April. Also a 2012 5.0 model.

According to the paper work these are the parts that were replaced.
22-32-6-780-026 B1SA Transmission bearing
27-10-7-643-752 SA Transfer box

I bet a lot of people here have failing transfer box and not even realizing it. Its easiest to tell when making a slow U-turn - the car with feel as if the tires as slipping.
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      07-04-2016, 09:41 AM   #11
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Quote:
Originally Posted by och
They replaced mine under warranty with 21,500 miles back in April. Also a 2012 5.0 model.

According to the paper work these are the parts that were replaced.
22-32-6-780-026 B1SA Transmission bearing
27-10-7-643-752 SA Transfer box

I bet a lot of people here have failing transfer box and not even realizing it. Its easiest to tell when making a slow U-turn - the car with feel as if the tires as slipping.
Yea I'm thinking of just unplugging it until I get a new one. Won't have 4 wheel drive but it's the summer time.
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      07-04-2016, 09:46 AM   #12
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Quote:
Originally Posted by -c- View Post
Yea I'm thinking of just unplugging it until I get a new one. Won't have 4 wheel drive but it's the summer time.
Can you elaborate? I'd rather mine was RWD!
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      07-04-2016, 12:02 PM   #13
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Quote:
Originally Posted by och
Quote:
Originally Posted by -c- View Post
Yea I'm thinking of just unplugging it until I get a new one. Won't have 4 wheel drive but it's the summer time.
Can you elaborate? I'd rather mine was RWD!
Yea the dealer just went under the front and unplugged the transfer case and the vibrations stopped so that's how they determined it was the transfer case. With the transfer case unplugged it failed to operate so the vehicle was smooth in tight turns again.

Since late 2013 their has been a new design released for our transfer case that supersedes all past designs (2011 - 2012 model ATC450). and is supposed to solve all issues from past models. So far their has been over 4 redesigns and the 2013 x5 model got an entirely new design that won't work with ours supposedly.
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      10-08-2019, 07:15 PM   #14
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Quote:
Originally Posted by bmw745 View Post
My friend , no need to change transfer case, all you have to do is to change small gear inside the transfer case , it's plastic part and it will not cost you more than 20$
Hi, i have shuddering issue with my wife's 2012 X5, referencing your quote, where can i find/buy the plastic part please.

txs
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      10-09-2019, 04:41 AM   #15
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Quote:
Originally Posted by Jack07 View Post
Hi, i have shuddering issue with my wife's 2012 X5, referencing your quote, where can i find/buy the plastic part please.

txs
This
https://www.amazon.com/gp/aw/d/B01MG...b_b_asin_title

And this:

https://www.amazon.com/gp/aw/d/B01N4...b_b_asin_title
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      10-19-2019, 05:11 PM   #16
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Quote:
Originally Posted by Jack07 View Post
Hi, i have shuddering issue with my wife's 2012 X5, referencing your quote, where can i find/buy the plastic part please.

txs
the plastic cog has nothing to do with the shuddering issue. The cog strips and causes ABS, Brake and 4x4 light to come on (i believe that's the 3). As said above, if its shuddering in turns then its a mechanical failure of the clutch assembly. You can try replacing the fluid and resetting the T-case adaptations but most likely it'll need to be rebuilt or replaced
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      10-19-2019, 10:38 PM   #17
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Quote:
Originally Posted by englishtom1596 View Post
the plastic cog has nothing to do with the shuddering issue. The cog strips and causes ABS, Brake and 4x4 light to come on (i believe that's the 3). As said above, if its shuddering in turns then its a mechanical failure of the clutch assembly. You can try replacing the fluid and resetting the T-case adaptations but most likely it'll need to be rebuilt or replaced
That is not correct. When the plastic gear strips, the adjustment arm in the transfer case will stay locked in its current position which is usually with sufficient pressure on the friction discs to cause the shuddering during slow speed turns.

This can easily be confirmed with a BMW OB2 reader like Foxwell NT510. It will show the current angle of the adjustment arm in the transfer case and it will not change when turning from very slow speeds as it should. On Mine the stripped gear did not cause any of the ABS/Brake/4x4 lights to come on but did throw a BMW specific code for the transfer case.
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      10-20-2019, 12:00 PM   #18
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Quote:
Originally Posted by Sophisticated Redneck View Post
That is not correct. When the plastic gear strips, the adjustment arm in the transfer case will stay locked in its current position which is usually with sufficient pressure on the friction discs to cause the shuddering during slow speed turns.

This can easily be confirmed with a BMW OB2 reader like Foxwell NT510. It will show the current angle of the adjustment arm in the transfer case and it will not change when turning from very slow speeds as it should. On Mine the stripped gear did not cause any of the ABS/Brake/4x4 lights to come on but did throw a BMW specific code for the transfer case.
interesting. I've never heard of the cog causing issues with the mechanical operation of the box, just the electronic sensing. I'll take your word for it
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      10-21-2019, 10:19 AM   #19
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Quote:
Originally Posted by Sophisticated Redneck View Post
That is not correct. When the plastic gear strips, the adjustment arm in the transfer case will stay locked in its current position which is usually with sufficient pressure on the friction discs to cause the shuddering during slow speed turns.

This can easily be confirmed with a BMW OB2 reader like Foxwell NT510. It will show the current angle of the adjustment arm in the transfer case and it will not change when turning from very slow speeds as it should. On Mine the stripped gear did not cause any of the ABS/Brake/4x4 lights to come on but did throw a BMW specific code for the transfer case.
Was your plastic gear issue with your 5.0? I thought the plastic gear issue was more common on the ATC700 transfer case that came with the 6 speed E70. I have not read about any plastic gear issues on the newer ATC450 that comes with the 8 speeds transmissions.
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      10-22-2019, 03:16 PM   #20
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I felt mine going out right before my CPO warranty was ending, so I played dumb at the dealer and said "it feels funny when turning sharp". They did the same "unplug and see if it goes away" test as above and confirmed my suspicion, then REPLACED my transfer case at no cost. Well, the $50 warranty deductible. Which I happily handed over.
That was at about 55k miles.
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      10-22-2019, 03:23 PM   #21
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Quote:
Originally Posted by smassey321 View Post
I have not read about any plastic gear issues on the newer ATC450 that comes with the 8 speeds transmissions.
The ATC450 TCs (which is what is on the 2011-12 X5) have a different actuator than the previous models.

Previously, the actuator looked like this:
Name:  ATC400 actuator.JPG
Views: 9214
Size:  20.2 KB
The motor (2) uses a worm gear to turn a regular gear (inside 4). That regular gear gets stripped and can be easily replaced (since the whole actuator unit can be removed from the TC).

The ATC450 actuator looks like this (#3):
Name:  ATC450 actuator.JPG
Views: 10282
Size:  46.9 KB
The actuator (3) is really just the motor. It turns a worm gear that turns a regular gear that is inside the TC itself, so there is no easy, $20 fix (at least as far as I have found).

I can confirm that disconnecting the wires from the actuator will make the shuddering at slow speeds problem go away...but it also disables ABS, DSC, etc., so is not a long-term solution. And without removing and cracking open the TC, I don't know if the shuddering is from a problem with the actuator (which would be an easy replacement), or is from one of the gears (which would require replacing or rebuilding the TC, I think).

The most reasonably priced rebuilt transfer case I've found is https://www.ebay.com/itm/BMW-X5X3-TR...oAAOSwYIxX23r2 ($1,450, but $400 is a refundable core fee) but it looks like it doesn't come with the actuator, so you would need to reuse the old one (or replace it for another $650-ish).

The process for replacing the TC looks straight forward:
1. Remove everything in the way (transmission support, covers, heat shield, exhaust).
2. Remove the drive shafts (from the engine, to the front, to the rear)
3. Unhook the wires to the TC
4. Unbolt the TC and remove it
5. The same in the reverse order

Nothing too complex, but looks like it would be difficult if you don't have a lift and some air tools.


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      11-17-2020, 07:53 PM   #22
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Quote:
Originally Posted by -c- View Post
Yea the dealer just went under the front and unplugged the transfer case and the vibrations stopped so that's how they determined it was the transfer case. With the transfer case unplugged it failed to operate so the vehicle was smooth in tight turns again.

Since late 2013 their has been a new design released for our transfer case that supersedes all past designs (2011 - 2012 model ATC450). and is supposed to solve all issues from past models. So far their has been over 4 redesigns and the 2013 x5 model got an entirely new design that won't work with ours supposedly.
I had this same issue, and same diagnosis with unplugging the TC and shuddering went away. I also tried pulling fuses. Mine is a 2011 35i with an ATC450. At first I tried changing fluid, which came out grey, but didn't help, so I did a full rebuild. At first removal of the TC, the failed mount fell out of its position. Pressing in a new TC mount would be an easier fix than a whole TC rebuild. Hope this helps everybody for yet another diagnosis.
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