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2007 E83 2.0 manual transfer case problems.

Discuss anything to do with the (E83) BMW X3 here
(Older F25 discussion within will ideally to be moved to F25 Sub section below)
Trav
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Re: 2007 E83 2.0 manual transfer case problems.

Post by Trav » Sat May 27, 2017 10:27 pm

Ok. So what the best way to confirm it is the transfer box before taking further action? I have had the prop shafts of spinning the flanges and can't feel any knocks.

Do the actuators/resistors ever go, or are the usually ok?

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kkx5
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Re: 2007 E83 2.0 manual transfer case problems.

Post by kkx5 » Sun May 28, 2017 6:01 pm

5F3A - DSC Transfer case malfunction.
5F39 - DSC Transfer case internal.
5462 - servo motor or coupling force too high

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Re: 2007 E83 2.0 manual transfer case problems.

Post by Trav » Sun May 28, 2017 7:47 pm

Yes but what I am asking is ...... Is there is any way I can test manually that would shine some light on the situation. Like a visual inspection, dropping  the oil and inspecting for fillings, or the likes? I have always been trained that a code only points you in the direction of the fault. Or is what you are telling me transfer case is the only possible fault. All I want to do is avoid the car becoming a money pit if you can get where I'm coming from because as it stands potentially £600 for tyre say £800 for TC all not know 100% if it's all going to fix it. More than aware that nothing is a sure thing with car diagnostics and it is always going to cost some Money. But no point on just throwing the stuff at it.

My concern being that if the servo force from the motor was to high that the plastic gear inside the servo would be stripped or at least slightly worn. Due to it being the weak point. So surely that code if the force too high was correct there would at least be slight damage?
Last edited by Trav on Sun May 28, 2017 7:54 pm, edited 1 time in total.

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Re: 2007 E83 2.0 manual transfer case problems.

Post by kkx5 » Sun May 28, 2017 8:21 pm

No, force too high mean tolerance set by vtg ecu is outside calibration. Plastic gear is not a weak point. Plastic is plastic for an reason but that is not your issue so i will not go any further with it. First gen of the xdrive system (x3 e83); When you switch engine off and then back on, DSC and VTG ecu sends signals to the transfer box motor to check calibration. It must be within tolerance set by system on calibration. If it fails, lights on dashboard and error codes.

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Re: 2007 E83 2.0 manual transfer case problems.

Post by Trav » Sun May 28, 2017 11:51 pm

Ok. Thanks for the input some very important questions answered. I will hopefully get home for next weekend, get it stripped and keep use posted with results.

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Re: 2007 E83 2.0 manual transfer case problems.

Post by Trav » Thu Jul 20, 2017 11:34 pm

Right people I recently got around to stripping and inspecting the transfer box. Not quite as much damage as I would have liked to see. (In regards to being certain this is 100% the fault is. The two bearings in the clutch pack were slightly pitted along with the spreader arms. The clutch itself looked a little worn (more so the pressure plates).

So I have got new bearings, clutch plates here ready to fit, have had the spreaders machined down so running surface is smooth to prevent premature wear of the new bearings and I am currently awaiting for engineering shims to arrive to replace what has been removed from the spreaders during machining process. Hopefully this fixes it, I will keep use posted tail end of next week.

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Re: 2007 E83 2.0 manual transfer case problems.

Post by kkx5 » Fri Jul 21, 2017 7:06 pm

It wont last long~1000miles will brake again. You can not use shims in clutch system.

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Re: 2007 E83 2.0 manual transfer case problems.

Post by gs223 » Thu Aug 17, 2017 10:55 pm

My TC problem was that cornering at slow speeds or reversing would cause grinding noises from the rear. I had the TC replaced with a S/H unit by Phoenix Transmissions of Scrubs Lane, London NW10 6RE incl parts & labour for £400+VAT. All good so far.
Last edited by gs223 on Thu Aug 17, 2017 11:08 pm, edited 1 time in total.
X3 2004 3.0i SE

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Re: 2007 E83 2.0 manual transfer case problems.

Post by Horizon » Fri Aug 18, 2017 6:40 am

[quote="gs223"]
My TC problem was that cornering at slow speeds or reversing would cause grinding noises from the rear. I had the TC replaced with a S/H unit by Phoenix Transmissions of Scrubs Lane, London NW10 6RE incl parts & labour for £400+VAT. All good so far.
[/quote]
Hi and welcome to the forum.
Do you have the Msport with the staggered setup, or are all the tyres the same size /profile /star marked.
When I bought my X3 Msport you could feel the transmission winding up.
I have fitted Identical new tyres all the way around so to guarantee the rolling resistance is perfect.
Much cheaper than going down the * marked route.
When I removed the old tyres, which were 3 different makes there was a 30/35 mm difference in rolling curcumferance.
Tyres seem to be the main culprit in wrecking transfer boxes, so isn't want you wrecking the replacement one as well.
2011 Kia Sorento KX3  2.2D 60 Plate Auto in black ( mine )
BMW E83 X3.  3.0d M Sport, 2008 in black ( now gone )
BMW E93 330i Convertible  Msport  2007.  ( Now sold )
VW Golf 2.0 TDI 140 GT 2010 ( now sold )
Now Sold 55 plate, X5, 3.0 D Sport. Silv

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Re: 2007 E83 2.0 manual transfer case problems.

Post by gs223 » Mon Aug 21, 2017 9:28 pm

Thanks for the welcome  :)

I've got 17" wheels with a complete set of standard size Zeta Alventi tyres (car is 2004 SE ~100K miles); they were relatively cheap and don't have a great reputation, but I was thinking of changing to 18" staggered at a later point.

Certainly skimming the internet indicates that odd-size or uneven wear tyres can be problematical.
Last edited by gs223 on Mon Aug 21, 2017 10:13 pm, edited 1 time in total.
X3 2004 3.0i SE

Horizon
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Re: 2007 E83 2.0 manual transfer case problems.

Post by Horizon » Mon Aug 21, 2017 9:50 pm

Better sticking with the same width tyres and rim widths to avoid transfer problems. I've got the different width rims as standard on the Msport.
I've fitted identical tyres on all 4 corners to eliminate problems with rolling circumference differences.
If you are considering larger rims, I have the 19" Msport rims, which will take 245/19's all round even though they are supposed to be for the staggered setup.
2011 Kia Sorento KX3  2.2D 60 Plate Auto in black ( mine )
BMW E83 X3.  3.0d M Sport, 2008 in black ( now gone )
BMW E93 330i Convertible  Msport  2007.  ( Now sold )
VW Golf 2.0 TDI 140 GT 2010 ( now sold )
Now Sold 55 plate, X5, 3.0 D Sport. Silv

Trav
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Re: 2007 E83 2.0 manual transfer case problems.

Post by Trav » Tue Oct 24, 2017 9:17 pm

[quote="kkx5"]
It wont last long~1000miles will brake again. You can not use shims in clutch system.
[/quote]

Got the transfer case back together quite some time ago after refitting took it to get programmed and it would not allow the computer to do its thing so the motor had to be replaced as well.

New motor and  on programmed works a treat with no warnings. The repair to the TC clutch pack solved the knocking. Shims fitted are now well in excess of 1500 miles and I was communicating with another person that used shims on a different forum. He said his shims had been installed for over 10,000 miles.

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Re: 2007 E83 2.0 manual transfer case problems.

Post by kkx5 » Wed Oct 25, 2017 7:27 pm

Did, as a try, well over 30 transfer boxes with shims on a clutch pack arms, all came back within a year under warranty....

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Re: 2007 E83 2.0 manual transfer case problems.

Post by Trav » Thu Nov 02, 2017 10:30 pm

Well only time will tell I suppose but I will be sure to keep you posted regardless.

Out of interest where were you placing the shims also how thick of a shim were you using?

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Re: 2007 E83 2.0 manual transfer case problems.

Post by Trav » Fri Nov 03, 2017 9:35 am

Also When doing the warranty job in which way had the clutch pack failed after using the shims?

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