How To Repair Bmw Transfer Case Modules

The following article gives detailed instructions on servicing the transfer case on a BMW E60 5 series xDrive (all bicycle drive) auto. Even though we have used a 2006 BMW 530xi to perform this service, this article can be applied to any E60/E61 5 series xDrive vehicle with pocket-sized modifications.

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The transfer case in your BMW xDrive (all wheel drive) vehicle is an electronically actuated set of gears that controls how much power is sent to the forepart and rear wheels. Information technology is situated behind the vehicle'due south transmission, approximately in the middle of the vehicle.

The BMW E60 transfer case is basically a third "middle" differential that redirects power from the transmission to the front and rear differentials. As power is fed into the transfer case from the manual it is distributed to the front and rear differentials in a twoscore%/60% split, respectively. If the rear wheels starting time to lose traction, more power is directed to the forepart then the commuter can remain in command of the vehicle.

The BMW E60 transfer case is not a maintenance-free component. In fact it is recommended that the transfer case fluid is changed every 5th oil modify (or every 50,000 miles). For those BMW owners that change their oil more than frequently than every 10,000 miles, we recommend using the 50,000-mile rule for servicing your transfer case and not the oil service interval.

How to fill the transfer case with new fluid

The normal procedure for filling the BMW E60 transfer case with new fluid is unfortunately a very difficult process. The fill plug is located on the upper right side of the transfer case to a higher place its mounting bracket. In order to properly remove the fill up plug, beginning, the exhaust arrangement must be lowered and the underlying oestrus shield removed. Next, the transfer case must be supported with a floor jack while its mounting subclass is taken off. Then everything must be put back together and torqued to the proper specifications to avert futurity issues with the drivetrain.

Not only is removing the fill plug a complicated procedure for the seasoned technician working under a hydraulic elevator, but it is too a nightmare for the abode mechanic lying on their dorsum underneath a auto with very limited workspace.

We have ever been very adamant at the BMW Repair Guide in fugitive "shortcuts" when maintaining our vehicles unless following the normal procedure is not practical and a suitable alternative method exists. Attempting to disassemble the frazzle organization and the transfer case mounting subclass to access its fill up plug is non a practical solution for the home mechanic...there is an easier procedure that produces the aforementioned end issue.

The BMW E60 transfer case can exist easily refilled through the drain plug with an inexpensive fluid transfer pump and prophylactic stopper with a hole drilled in the middle of it. Refilling your transfer case through the drain plug is so elementary, information technology turns a three-iv hour repair into a procedure that can be done in almost 45 minutes. There are no brackets that need to be removed...simply empty the old fluid and refill the case through drain pigsty. The following video shows how to practise information technology. Delight run across our Tools and Supplies list beneath for a complete inventory of what you will need to perform the drain plug refill. In Section 2 of the repair we give detailed footstep by step instructions and video on how to perform the bleed plug refill likewise.

Department one - Draining the BMW E60 Transfer Case

Draining the transfer example in your BMW E60 v series is a relatively easy procedure. You will need to jack and back up your vehicle on ramps or stands and then you have enough room to get underneath the auto. Remember...this is a messy task. Nosotros highly recommend performing this repair somewhere you don't listen getting muddied.

Jack and back up your car at all four wheels using wheel ramps or stands. The BMW Repair Guide does non recommend using jack stands to support your vehicle unless the wheels need to be removed for the repair. For more information on jacking and supporting your vehicle, please see our article BMW Jacking and Supporting for Repairs and Maintenance.
Remove the engine (front) belly pan. The abdomen pan is held in place on the BMW E60 with phillips head screws.
Using an 8mm nut driver, remove the underfloor (rear) belly pan from the lesser of the machine.
Locate the transfer case. It is mounted to the rear of the transmission in approximately the center of the vehicle.
Locate the bleed plug located on the lower front of the transfer case.
The drain plug requires a 14mm hex socket for removal. Unfortunately, there is not plenty clearance between the transmission oil pan and the transfer example to get a standard 14mm hex socket into the plug (see epitome below). The BMW Repair Guide recommends an like shooting fish in a barrel shortcut to solve this problem...cut the finish off of a 14mm hex socket and apply a 14mm boxed end wrench to remove the plug. With a little assist from a prophylactic mallet (the plug is normally torqued very tight), it will quickly break costless.
Remove the plug and permit the transfer case to thoroughly drain into a large plastic cup. Do no utilize a drain pan to capture the one-time fluid...you may want to reuse the fluid to practice refiling the transfer case through the bleed hole (we know this sounds disruptive, so please encounter section two below for more information).

Section ii - Refilling the BME E60 Transfer Case with New Fluid

As discussed at the starting time of this article, we strongly feel that removing the exhaust and the mounting subclass to refill the transfer case is completely unnecessary. Refilling the transfer case through the drain hole is quick, easy, and the all-time option for the home mechanic. If this is your first fourth dimension refilling the transfer instance using this method, we strongly recommend doing a test run with the old fluid that was drained out in Section 1 - footstep 7 above. Once over again, we encourage our readers to watch the following video and review the below steps before starting the process.

Before refilling the BMW E60 transfer example, you will demand to put together a uncomplicated device that volition let yous to pump fresh fluid in without it spilling out. This tin can be easily achieved with an cheap condom stopper (i"x 3/four" ten 1") and a paw transfer pump. By drilling a seven/16" (11mm) hole in the center of the rubber stopper with a paddle flake, the transfer pump hose can be inserted securely into the transfer case without using the difficult to access fill plug.
The offset stride is to drill a hole in the heart of a safety stopper. The rubber stopper should take the post-obit estimate dimensions: 1" (top width) x 3/4" (bottom width) ten ane" (total length).
Using a 7/16" (11mm) paddle bit, advisedly drill a hole directly through the centre of the rubber stopper. Try and continue the hole in the centre of the stopper equally best every bit you can.
Insert the rubber stopper most half way into the transfer instance drain hole. You want it slightly snug, but non too tight. If it is too tight you won't be able to insert the transfer pump tubing in the side by side step.
Cut off a six" piece of the tubing that comes with the transfer pump (it is easier to pump the fluid in with a shorter piece of tubing). Firmly insert the tubing into the safety stopper.
Attach the transfer pump to the tubing in the safety stopper. Run another slice of tubing from the pump to a canteen of BMW DTF1 transfer case fluid (or if yous are doing a test run...to the plastic cup of former fluid). If you have a helper bachelor (like this fine gentleman in the epitome below), have them hold the canteen of transfer case fluid then it doesn't tip over while yous pump it.
Using irksome and deliberate strokes, pump the entire 1 liter container of fluid into the transfer case. We recommend pumping the unabridged bottle into the instance because a portion will be lost when removing the prophylactic stopper and reinstalling the new bleed plug.
When the transfer case is total of fluid, remove the pump and tubing from the rubber stopper. Block the hole in the rubber stopper with your finger to continue fluid from escaping.
In one quick motion, remove the rubber stopper from the bleed pigsty and insert the drain plug. Put pressure level on the drain plug with two fingers while slowly turning it clockwise until it is snug. You lot will lose some fluid during this procedure but don't panic...since yous pumped the entire i liter bottle in you take plenty to spare. Technically the transfer box is suitably filled with ane/2 liter of fluid, so unless you lose more fifty% of what you pumped in yous are in good shape. Once over again, if yous are nervous about this step, do a trial run with the one-time fluid removed in Department i.
Using a torque wrench and a 14mm crows foot socket, torque the drain plug to 60 Nm (44 ft-lb).
You tin can now reinstall the forepart and rear belly pans.