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  #1  
Old 06-30-2008, 03:51 PM
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2002 x5 transfer case/front drive shaft problem

My x5 has 72,000 miles on it and the splines on the front drive shaft and the splines on the transfer case have rounded off making the x5 not drivable. Has anyone else experienced this?
What would cause this to happen?
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  #2  
Old 06-30-2008, 04:02 PM
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Do you have a 4.4i?
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Old 06-30-2008, 04:42 PM
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No it has a 3 liter
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Old 12-10-2008, 02:08 PM
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My 2001 3.0 X5 with 103k miles has developed the same problem. Is there anywhere other than the dealer to get a front drive shaft from. I have found a rebuilt transfercase at www.trasnfercases.com
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Old 12-10-2008, 03:12 PM
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I have researched this issue along with another mechanical concern on my 2001 4.4. The root cause is the moisture ingress into the slip joint between the driveline splines and the tranfercase interface. The moisture causes corrosion and both the driveline and tranfercase spline begin to deteriorate until they fail. The secondary issue is that driveline only engages about the first inch of the splined transfer case slip joint although this mating hole is over 1 1/2" deep. The driveline is stationary so I would consider this a design flaw.

I have talked to transfercases.com and they do have rebuilt units readily available for about $875. Since I am looking into this for a different problem I don't have any information about where to source the driveline other than stealer.

Hope this helps.

BTW. I believe your transfercase is an NV125 made by New Process/Venture Gear. You will need to validate this by looking at the aft area of the transfercase. The label is about 1 1/2" diameter with red/black text.
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  #6  
Old 01-07-2009, 02:23 AM
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I found this thread 26 pages in and was about to give up because i thought i was the only one with this problem. I have an '01 4.4i with the sport pkg., 95,000 miles. same problem, started my new years eve off great. Has anyone tried to fix with a custom shaft with "fresh" longer splines to get into the good one's still in the coupler, there appears to be just as much in there as to what was used in the first place. I'm currently in the process of fabricating a repair end with longer splines to repair my existing drive shaft. After some testing and if there's enough interest i might do some on an exchange basis. It would be nice to fix without buying an $800+ transfer case. Btw, I just loved having to remove 75% of the underside out just to remove the front shaft, great engineering! I really love driving it, but i've fixed more than half of the common problems i've been reading about and i'm getting sick of working on it.
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  #7  
Old 01-07-2009, 11:16 AM
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Quote:
Originally Posted by racemalibu572
Btw, I just loved having to remove 75% of the underside out just to remove the front shaft, great engineering!
75%??
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  #8  
Old 01-07-2009, 11:19 AM
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This is the sort of failure that has a good shot at goodwill from BMW.
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  #9  
Old 01-07-2009, 01:52 PM
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I had mine fixed. Originally, I had taken it to the dealer and he said it needed a new transfercase and a front drive shaft. He quoted me $4300 plus tax. This seemed like a little too much to put into an '01 car with 103k miles so I had it towed to an AAMCO that a family member had used for a repair. I ordered the transfer case myself from transfercases.com (for $895)and I found a used front drive shaft with 65k miles in great condition (for $300). The whole repair was done with parts and labor (about $500) for under 2k and now the car is working great again.
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Old 01-07-2009, 01:55 PM
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Also, I did call BMW North America directly and the person was very receptive to hearing about my problem with the transfercase and drive shaft but said there was nothing he could do about it and there was no recall on these parts even though several people on the forums have indicated some shortfalls in the design of these parts on the X5
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