BMW X3 Transfer Case Rebuild

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This is a video on how to rebuild your BMW X3 Transfer Case (ATC-400) I got my bearings for here: www.americanpowertrainwarehouse.com/bmw-x3-w-tod-atc-400-transfer-case-chain-fits-03-borg-warner-hv-086-made-in-usa/
and the Bearing Kit here: cobratransmission.com/bmw-x3-bearing-kit-55133001-1
UPDATE: Before you take the transfer case apart, use a cardboard drawing of the case and when you extract each bolt, stick it through the cardboard. This will guarantee that when put it back together you will put the bolts in the correct location. (You can see my cardboard cut out at 5:35 in the video) The Gary Sealant that you use to seal the case is Permatex Ultra Grey Gasket Maker.

Опубликовано:

16 фев 2015

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Комментарии : 98

@toomuchinformationforu9919 4 года назад

I know this is 4 years since you posted but just wanted to say thank you ,if you are not an educator of some kind then you should be ,very clear and very informative and hey ,you saved me $4,000

@teslacube 7 лет назад

thanks. next vid get a camera stand please. good work bro.

@M6BrokeMe 3 года назад

Looks very simple. Thanks for the info.

@MrADD-mi1cw 5 лет назад

Hi Sean, Great Video! By any change do you know the trasnfer case model on the Mini cooper All4 Countryman s AT... I've been looking for a rebuild kit, but no look...

@TheEZFix 9 лет назад

Thanks for the video it is really helpful.

@linsey4444 3 года назад

On the front output shaft: is there any way that it specifically attaches (clip/bolt) or is it kept in place simply by pressure?

@nicks8565 5 лет назад

Good video. I may need one too. Can you or someone HELP answer a question for me. My 07 x3 3.0si is rattling at the center bottom of the vehicle at rpm's at about (12-1500) in park, drive, neutral also while moving. IDK if the Transfer case has any power or movement to it while in park. I had the car up flushing my brake fluid and friend gave it gas in P, N, and Drive and it was way louder than I thought. Sounds like bad bearings or marbles inside somewhere right on or near the T.C.. The Exhaust is right next to it and was just wondering if it's that nylon worm gear, Transfer case or possibly Cat Convertor or even Torque Converter? going bad. Any help would be greatly appreciated. Thanks-Peace-

@nathanielmoore5677 3 года назад

Hi guys random atc400 functionality question. Without the actuator on the t case the spreaders are closed, does this fully engage front drive shaft or fully Disengage it? And is it safe to say that fully spread is the opposite?

@mR_Reddexe 2 года назад

that's awesome! thank you for showing this

@TheSponge945 5 лет назад

What are some symptoms when this t-case fails? My X3, 6speed when put in gear simple does not move. I can shift into all gears and its smooth however as I let the clutch out I hear noise coming from what sounds like the t-case. And does this apply to a 08 X3? Looking at realOEM it lists the ATC400 for years 2003-2010

@JumboJimbo100 4 года назад

It came together by magic. My dealership wants $8000 to replace the transfer case, I found a transmission shop that will replace the bearings for about $1000.

@andreis3282 3 года назад

Unbelievable. For this money you can buy parts here awd.tech/collections/atc-400-bmw-x3 and repair 10 transfer cases :)

@glenglene8473 Год назад

Everything in my transfer case is OK except the chain. I replaced the chain for less than $100 and car back on the road.

@LynxStarAuto Год назад

Yeah I usually rebuild the entire thing for 1500 out the door. That includes new mount, bearings, chain, seals, and labor.

@aurimasbelij1712 Год назад

@@glenglene8473could you tell me where you buy the chain? Thanks

@davidfoley326 7 лет назад

Sean- did you have problems when joining the two halfs together with the washer that goes on the bottom of the shaft not lining up? It's the one that sits on top of snap ring at the bottom of the shaft on top of the bearings

@guillermomulgrave7330 2 года назад

Question(My 2007 x3): My transfer case was changed to a used one and it removed the ABS/Brake/4x4 lights from being on. Now I hear a scratching sound from the back that was NEVER present before. Do you have a professional opinion what could be happening or what could be checked?

@ChongDM 5 лет назад

The black pipe that is on top and outside of the TC, does that attach to anything or does it hang free?

@abimmernut 9 лет назад

What kind of "gray" sealant did you use?

@laurentxxx341 6 лет назад

Hi thank you. this video is usefull. shouldn't you align the holes of the input shaft (2'34) and the holes of the drum (1'48)? I guess those holes are made to lubricate the Sprocket Assembly and the gear

@houseofgrace8797 7 лет назад

Where can i buy transfer components for BMW X5 2001 model?

@meSteveGuy 8 лет назад

Did you replace oil seals as well? Where to buy them?

@d5nyel890 8 лет назад

You need RTV to seal both parts of housing

@timdachtera 4 года назад

Hello Sean - I am trying to troubleshoot my ATC400, and wondering should the assembly at timepoint 3:59 allow the input shaft from the servomotor to rotate a full 360, or should there be some resistance from the clutchpack limiting the rotation? I've replace my servomotor and ECU, get the TC still will not calibrate. Debating if I'm going to drop the TC or just send the car down the road. Great video!

@miketurin5233 4 года назад

There should be tough resistance when you turn the shaft where the Serv motor connects. It should turn back really fast and hard once you turn it with your hand.

@vitorhugolencione9961 5 лет назад

hi, i need to buy one to the X5 2002 3.0, please send me the link.

@richardhyde6418 6 лет назад

Cool Beans Man.....Great Video........I can drive to you and have U do it for me......I'll pay ya $500 LOL........How long to remove the transfer case and re-install? Thanks for posting, well narrated and good video.

@MisterGenie21 9 лет назад

Great video for the world

@irishyouwherehere7934 6 лет назад

Way to stick it to those dealerships! Those poor mechanics that work for BMW are getting pennies compared to what's charged. Btw, is it safe to drive without resetting the transfer case adaptations though? I might have to go to the dealership to reset everything since I don't have a diagnostic tool.

@richardhyde6418 5 лет назад

Can I please ask what the original issue/noise was.......

@johnm948 8 лет назад

What were the symptoms that had you do the rebuild? Great information here. I am getting some clunking and I am going to replace the fluid to see if that will work before I yank it out. A little initiative, a good back ground in auto repair and you can save a fortune.

@seanbking 8 лет назад

clunking was definitely one big indicator for mine too. if/when you drain the fluid you should be able to see the chain through the filler hole. if you're able to move the chain easily with a screwdriver etc..then the chain needs replacing. also if the Christmas lights of death come up on the dash and it only lets you drive in 2Wd, the n it could be the transfer case actuator gear..which is only a 25 fix. there are plenty of videos about that on you tube.

@Tablesoccerplayer 6 лет назад

Sean King what about if it does like a chugging or hopping movement? and also all the lights of death are on also!

@cs3943 5 лет назад

did you have a vibration? rear and front, rear or front?

@miketurin5233 4 года назад

This jerking was one of my symptoms too. When driving up a hill fast.

@fadi_koka 6 лет назад

From where you get the parts

@zinhom88 7 лет назад

many many thanks .

@tahsom5106 4 года назад

So what was the torque spec video was cut off

@newcavemen6682 6 лет назад

Good video! I'm trying to do the same for my 2005 X3 as well. Ran into a couple of problems though. One is that one of the bolts broke and I'm having a tough time trying to get it out. Tried a few things but it won't get out. Then i thought i would just open it up and hopefully i can just twist it and get it out that way. But now I'm having trouble separating the two halves. The video says a puller is used. May i ask what kind of puller would work? I have a few pullers but they seem to be way too short/small to be secured against the case.

@cs3943 5 лет назад

Try a razor to get started, then try a small strong plastic spackle knife or gasket remover tool in the center of the T-Case.

@gazlough 7 лет назад

Hey Sean, ive got an oil leak on my t/c its coming from the front output shaft oil seal ( the smaller shaft in your video) would I have any issues pulling that shaft out when the transfer case is on the car? does the gear sit inside the bearing or will it fall out of place when the shaft is removed ?

@georgelefter 6 лет назад

hi, i have the same problem, did you sorted out, if yes, how?

@mr2010cm 7 лет назад

@sean king, I have a 2007 bmw x3 3.0 4wd automatic, would the kits from the links work on mine?

@seanbking 7 лет назад

I don't think it would. I believe the model changed to the new one in 2007??

@LynxStarAuto 6 лет назад

with the face lifted models, the transfer case was redesigned, and no longer uses a chain. Rather it uses gears which spline together. When these units fail, more than likely, not going to be worth rebuilding. Unfortunately, you have to replace the whole unit.

@dmirocha 6 лет назад

Hello. Dealer just called with a $4500+ replacement cost of the ATC400 transfer case. This video is a lifesaver. The car was studdering or jumping during acceleration and very occiasionally flashing a 4x4 light. I have already replaced the plastic gear in the xcase motor actuator. After watching this video I am imagining that the chain is jumping teeth. Is that a fair assumption? Other than the chain and bearing kit, what about the seal kit? Would that be a plus to replace? Also, are these case bolts aluminum and require replacement after every torque up? And finally, is the sealant for the case half the same that they use on the differential cover (loctite 5970) now? Great video and thanks for the info.

@seanbking 6 лет назад

Darby Mirocha it's probably a lose chain. The seals I didn't replace because they weren't leaking. If yours aren't I'd leave them be. The gray sealant is permatex ultra grey. Reuse the same bolts.

@dmirocha 6 лет назад

Thanks so much. One more thing. I am using loctite 5970 for the case half. What is the cure time before filling with fluid? The MSDS says 7 days before subjecting to 'heavy loads'. I don't think an non-pressurized transfer case is a heavy load, but I don't want to be impatient either. How long did you wait before filling with fluid?

@cs3943 5 лет назад

@@dmirocha "Form a Gasket." has different drying times. The case is bolted so can't emagine you would need a rocket ship type. But I would use the best auto Gasket Maker. Did you get vibrations in the seat and front of car?

@ozusozudogruinsan 2 года назад

What are wear items in this transfer case? Why was there a need to do this rebuild?

@georgeekonomakos3124 Год назад

Thanks for the video but couldn't help but notice At 2:19 seem to me that the snap ring is deformed and out of shape! Just an observation

@GerardoLopez-bv9mh 8 лет назад

do you have to remove something before you can open it?? I opened mine and broke where the c clip gose

@miketurin5233 4 года назад

That happened to me too. Apparently you have to remove the flange from the input shaft first and pull out the input shaft so the bearing remains in place with the C clip inside.

@bhmax16 9 лет назад

This is great. I have a 2007 328xi, which has the ATC300 transfer case. My front output flange bearings are shot, so I will be pulling my transfer case soon to replace them. The site you listed, Cobra Transmission, lists a bearing kit for the ATC300 but specifies X3 and X5. I'm assuming this kit should fit my 328xi since it appears to use the same transfer case, yes?

@jpjp7901 7 лет назад

I also have a 2007 328xi. My car vibrates badly on the highway, on acceleration. When I take my foot off the gas pedal, there is no vibration. What were the symptoms with your 328xi?

@cs3943 5 лет назад

@@jpjp7901 I'm having the same problem. Vibration, Started in the rear, now in the front and rear. Happens on acceleration and deceleration, gets a bit better on highway. Did you ever find out what it was? Transfer case, Center support, Guibo, motor mounts, etc...???

@cuneytmenekse9980 6 лет назад

What if I have to replace the clutch pack as well. Not the whole assembly, only the clutches. How can it be done? Any specialty tools needed for the clutch pack?

@seanbking 6 лет назад

CeCO Jr. Sorry for the delayed response. No tools necessary for the clutch pack. Just make sure to take pictures of the order of the stack so when you get new ones, they're in the correct orientation.

@cuneytmenekse9980 6 лет назад

Sean King Thank you. 👍

@Tablesoccerplayer 6 лет назад

So I did this and old chain stretched to 3 1/2 and new chain to 3 5/8 so can only 1/8 difference between the new and old chain make the difference? Or did I just wait my time buying a new chain?

@seanbking 6 лет назад

Chad Ditsworth if you opened it up, it's not a waste of time, if you only replaced the chain, probably a waste of time. The bearings will make noise too. You have to replace them.

@Tablesoccerplayer 6 лет назад

Sean King I didn’t open it up because of any noise problems, all it was doing was jumping and jerking like the chain wasn’t gripping! So with that 1/8 difference the new chain made help my situation?

@Epierson321 8 лет назад

how heavy is the transfer case? is it a two person job to get it back in the car?

@seanbking 8 лет назад

it's not that heavy. you should be able to easily move it yourself.

@RandyLittleStudios 7 лет назад

What about the Seal kit? you didn't need new seals?

@seanbking 7 лет назад

My seals weren't leaking so I used the old ones. No issues.

@dougvitagliano7512 6 лет назад

So two years later, do you still have the car? If so, how are the parts holding up? Shop quoted me $3800 To replace the whole trans case. Thy said they use to service them but they won't do it anymore because they've been unreliable and later fail again. Thanks in advance!

@seanbking 6 лет назад

I sold the car. No know issues I'm aware of. In hindsight, I would have replaced the Clutch pack too since I had it all apart and replaced everything else. I wouldn't buy into the"unreliable" rebuild theory of the dealership. A new transfer case is almost more than the car is worth! If I can rebuild it, you can too!

@amycarolus6557 3 года назад

@@seanbking vn

@johnfisher1609 3 года назад

Typiocally you do not want to use the cheap chains on these. Perhaps the oner you got was ok but you really want to use the original Borg Warner branded chains.

@KevinMcCarley 9 лет назад

How long did it take you to replace the bearings and chain? I have a X3 that has a loose chain and also makes some noise. I've never done one before. Thanks

@seanbking 8 лет назад

+Kevin McCarley (vwauditech) Once out of the car it probably took about an hour to replace the bearings.

@KevinMcCarley 8 лет назад

+Sean King Thanks.

@atlanticearthaerials6197 8 лет назад

+Sean King Hi Sean, Did you need a special tool to press the bearings in/out of the transfer case? Or do they basically drop right into place?

@KevinMcCarley 8 лет назад

Brady Baxter they do require being pressed in/out. It doesn't "require" any special tools, just press plates sufficient enough to do the job. I actually just did another chain and motor gear job on E83 yesterday. $15 for a new gear and $85 for the chain. Took 2.5 hours. Winning!

@Tablesoccerplayer 6 лет назад

So I did this and old chain stretched to 3 1/2 and new chain to 3 5/8 so can only 1/8 difference between the new and old chain make the difference? Or did I just wait my time buying a new chain?

@nissy4 4 года назад

What is the most commen symptoms of a faileur in de case?

@miketurin5233 4 года назад

Mine was jerking/stuttering when going up a hill under pressure. Also I had a noise like plonk/plonk coming when rolling slowly and shift in N and then push/pump the throttle and release. Felt like a rubber band release. Also disconnect your transfer case by disconnecting the electric gear motor in the transfer case. It’s just a plug and can be done quickly under the car. No need to jack up. You car will drive in rear wheel mode only. If any symptoms are gone then it’s the transfer case.

@pedrogregorio 8 лет назад

Hello! Im planning on doing this job on my 04 X3 -- we've got a large knocking noise at low rpm upon acceleration and let off. Is taking out the transfer case the hardest thing? Also what kinds of tools does the job require? Any specials ones?

@seanbking 8 лет назад

you'll need a torx set for the screws, snap ring pliers for the snap rings, and a puller to separate the cases. if you are replacing the bearings, you'll need a press to press them in place.

@jean-paulgedeon8195 7 лет назад

Can you email me pics of your Puller, Snap Ring Pliers and Torx set? jpg@jpghawaii.com I am going to try to do this myself.

@nathanielmoore5677 3 года назад

Did you replace the clutch pack at the same time? That seems to be the most expensive part.

@victoroliva1266 4 года назад

Perfecto

@montanamontana6118 3 года назад

You don't show how to put the two parts all toghether....😪

@carl9239 7 лет назад

hi where can i buy the parts to rebuild mine

@bsaurusrex 7 лет назад

cobratransmission.com/index.php?main_page=index&cPath=3_2203

@carl9239 7 лет назад

thank you i also have another question.. i changed my transfercase and motor i still have the same banging and hoping feel what do you suggest im thinking replacing tie rods and tires and alignment

@darshaun93 9 лет назад

Where do you get the sealant? And where do you get the torque specs?

@d5nyel890 8 лет назад

50 Nm for the studs

@mikehan7428 6 лет назад

can i send you my transfer case so u can rebuild it for me and ill pay you?????

@isrealperez9069 7 лет назад

why did u needed to rebuild you're transfer case

@ShayTBD 7 лет назад

Isreal Perez transfer case and transfer case actuator are notorious for going out in this model year range. 4x4, abs, airbag and another light on dash will all come on along with a clicking when you turn vehicle off, left and right turning/cornering stiffen/grind...

@Kbcqw 6 лет назад

the actuator is a notorious, common fault with e83s but the transfer case going bad isnt at all common... and the only reason the actuator goes is because some idiot engineer designed the worm gear to be made out of plastic (the motor itself doesnt go bad). plastic gear next to catalytic converter = bad news.

@toomuchinformationforu9919 5 лет назад

sort of like a puzzle ,you show half of everything ,I know you are trying to help but get a camera stand and explain all the moves as well as show ,this is very frustrating to non mechanics and I still have no idea