BMW X5 2000-05

Transfer Case Removal & Installation

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  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the transmission fluid.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust system
     
    Front splash guard
     
    Reinforcement plate
     
    Heat shields and unclip the Oxygen (O 2 S) sensor
     
    Stabilizer bar and slide it forward
     
    Rear heat shield
     
    Front propeller shaft and unclip the vent line from the transmission. Properly support the transmission.
     
    O 2 S cable from the transmission crossmember
     
    Transmission crossmember
     
    O 2 S cable from the transfer case
     
    Center bearing after bracing the properller shaft. Do not allow the propeller shaft to damage the CV-joints.
     
    Transmission output flange by bending the propeller shaft downward at the center bearing
     
    Transfer case from the transmission
     

  6.  

To install:

  1. Connect the transfer case to the transmission. Torque the bolts as follows:
    1. M8 Hex screws: 18 ft. lbs. (24 Nm).
    2.  
    3. M10 Hex screws: 33 ft. lbs. (45 Nm).
    4.  
    5. M12 Hex screws: 60 ft. lbs. (82 Nm).
    6.  
    7. M8 Torx bolts: 16 ft. lbs. (21 Nm).
    8.  
    9. M10 Torx bolts: 31 ft. lbs. (42 Nm).
    10.  
    11. M12 Torx bolts: 54 ft. lbs. (72 Nm).
    12.  

  2.  
  3. Install or connect the following:

    Transmission output flange
     
    Center bearing. Torque the bolts to 16 ft. lbs. (21 Nm).
     
    Transmission crossmember. Torque the bolts to 16 ft. lbs. (21 Nm).
     
    O 2 S cable to the crossmember
     
    Union screw to the oil return line. Torque the screw to 21 ft. lbs. (28 Nm).
     
    Front propeller shaft. Torque the bolts to 47 ft. lbs. (64 Nm) and clip the vent line to the transmission.
     
    Rear heat shield
     
    Stabilizer bar. Torque the bolts to 16 ft. lbs. (22 Nm).
     
    Front heat shields
     
    O 2 S connector
     
    Reinforcement plate
     
    Front splash guard
     
    Exhaust system
     
    Negative battery cable
     

  4.  
  5. Fill the transmission with the proper fluid to the proper level.
  6.  
  7. Start the vehicle and check for leaks, repair if necessary.
  8.  

3.0L Engines



With Manual Transmission
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust system
     
    Heat shield at right front
     
    Heat shield at rear
     
    Reinforcement plate from undercarriage
     
    Stabilizer bar
     
    Front propeller shaft
     

  4.  
  5. Support the transmission

    Crossmember
     
    Vent line from transfer case
     
    Driveshaft-to-transmission flange nuts and discard the nuts
     
    Propeller shaft nuts, bend shaft downward at center bearing
     
    Propeller shaft from transmission and tie aside
     

  6.  
  7. Support the transfer case. Remove the retaining bolts and remove the transfer case.
  8.  

To install:

  1. Check the condition of the dowel pins and replace if necessary.
  2.  
  3. Be sure the mating surfaces are clean.
  4.  
  5. Apply a thin coat of grease to transfer case splines
  6.  
  7. Replace the sealing ring of the driveshaft of the transfer case.
  8.  
  9. Install the transfer case and torque the retaining bolts to 32 ft. lbs. (43 Nm).
  10.  
  11. Reposition the propeller shaft in the center support bearing and to the flange. Torque the center support bearing nuts to 15 ft. lbs. (21 Nm) and the flange nuts to 24 ft. lbs. (32 Nm).
  12.  
  13. Install or connect the following:

    Cable to transfer case
     
    Vent line
     

  14.  
  15. Install the transmission crossmember. Torque the bolts as follows:
    1. To rubber mounts: 55 ft. lbs. (74 Nm).
    2.  
    3. To body: 30 ft. lbs. (41 Nm).
    4.  

  16.  
  17. Install or connect the following:

    Propeller shaft
     
    Front stabilizer
     
    Reinforcement plate
     
    Heat shields
     
    Exhaust system
     

  18.  
  19. Refill the transfer case.
  20.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust system
     
    Heat shield at right front
     
    Heat shield at rear
     
    Reinforcement plate from undercarriage
     
    Stabilizer bar
     
    Front propeller shaft
     

  4.  
  5. Support the transmission

    Crossmember
     
    Vent line from transfer case
     
    Driveshaft-to-transmission flange nuts and discard the nuts
     
    Propeller shaft nuts, bend shaft downward at center bearing
     
    Propeller shaft from transmission and tie aside
     

  6.  
  7. Support the transfer case. Remove the retaining bolts and remove the transfer case.
  8.  

To install:

  1. Check the condition of the dowel pins and replace if necessary.
  2.  
  3. Be sure the mating surfaces are clean.
  4.  
  5. Apply a thin coat of grease to transfer case splines
  6.  
  7. Replace the sealing ring of the driveshaft of the transfer case.
  8.  
  9. Install the transfer case and torque the retaining bolts to 32 ft. lbs. (43 Nm).
  10.  
  11. Reposition the propeller shaft in the center support bearing and to the flange. Torque the center support bearing nuts to 15 ft. lbs. (21 Nm) and the flange nuts to 24 ft. lbs. (32 Nm).
  12.  
  13. Install or connect the following:

    Cable to transfer case
     
    Vent line
     

  14.  
  15. Install the transmission crossmember. Torque the bolts as follows:
    1. To rubber mounts: 55 ft. lbs. (74 Nm).
    2.  
    3. To body: 30 ft. lbs. (41 Nm).
    4.  

  16.  
  17. Install or connect the following:

    Propeller shaft
     
    Front stabilizer
     
    Reinforcement plate
     
    Heat shields
     
    Exhaust system
     

  18.  
  19. Refill the transfer case.
  20.  

4.4L & 4.6L Engines



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the transmission fluid.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust system
     
    Front splash guard
     
    Reinforcement plate
     
    Heat shields and unclip the oxygen sensor
     
    Stabilizer bar and slide it forward
     
    Rear heat shield
     
    Front propeller shaft and unclip the vent line from the transmission. Properly support the transmission.
     
    Oxygen (O2s) sensor cable from the transmission crossmember
     
    Transmission crossmember
     
    O2s sensor cable from the transfer case
     
    Center bearing after bracing the properller shaft. Do not allow the propeller shaft to damage the CV-joints.
     
    Transmission output flange by bending the propeller shaft downward at the center bearing
     
    Transfer case from the transmission
     

  6.  

To install:

  1. Connect the transfer case to the transmission. Torque the bolts as follows:
    1. M8 Hex screws: 18 ft. lbs. (24 Nm).
    2.  
    3. M10 Hex screws: 33 ft. lbs. (45 Nm).
    4.  
    5. M12 Hex screws: 60 ft. lbs. (82 Nm).
    6.  
    7. M8 Torx bolts: 16 ft. lbs. (21 Nm).
    8.  
    9. M10 Torx bolts: 31 ft. lbs. (42 Nm).
    10.  
    11. M12 Torx bolts: 54 ft. lbs. (72 Nm).
    12.  

  2.  
  3. Install or connect the following:

    Transmission output flange
     
    Center bearing. Torque the bolts to 16 ft. lbs. (21 Nm).
     
    Transmission crossmember. Torque the bolts to 16 ft. lbs. (21 Nm).
     
    O2s sensor cable to the crossmember
     
    Union screw to the oil return line. Torque the screw to 21 ft. lbs. (28 Nm).
     
    Front propeller shaft. Torque the bolts to 47 ft. lbs. (64 Nm) and clip the vent line to the transmission.
     
    Rear heat shield
     
    Stabilizer bar. Torque the bolts to 16 ft. lbs. (22 Nm).
     
    Front heat shields
     
    O2s sensor connector
     
    Reinforcement plate
     
    Front splash guard
     
    Exhaust system
     
    Negative battery cable
     

  4.  
  5. Fill the transmission with the proper fluid to the proper level.
  6.  
  7. Start the vehicle and check for leaks, repair if necessary.
  8.  

4.4L (M62) & 4.6L Engines



  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Drain the transmission fluid.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust system
     
    Front splash guard
     
    Reinforcement plate
     
    Heat shields and unclip the oxygen sensor
     
    Stabilizer bar and slide it forward
     
    Rear heat shield
     
    Front propeller shaft and unclip the vent line from the transmission. Properly support the transmission.
     
    Oxygen (O 2 s) sensor cable from the transmission crossmember
     
    Transmission crossmember
     
    O 2 s sensor cable from the transfer case
     
    Center bearing after bracing the drive shaft. Do not allow the propeller shaft to damage the CV-joints.
     
    Transmission output flange by bending the propeller shaft downward at the center bearing
     
    Transfer case from the transmission
     

  6.  

To install:

  1. Connect the transfer case to the transmission. Torque the bolts as follows:
    1. M8 Hex screws: 18 ft. lbs. (24 Nm).
    2.  
    3. M10 Hex screws: 33 ft. lbs. (45 Nm).
    4.  
    5. M12 Hex screws: 60 ft. lbs. (82 Nm).
    6.  
    7. M8 Torx bolts: 16 ft. lbs. (21 Nm).
    8.  
    9. M10 Torx bolts: 31 ft. lbs. (42 Nm).
    10.  
    11. M12 Torx bolts: 54 ft. lbs. (72 Nm).
    12.  

  2.  
  3. Install or connect the following:

    Transmission output flange
     
    Center bearing. Torque the bolts to 16 ft. lbs. (21 Nm).
     
    Transmission crossmember. Torque the bolts to 16 ft. lbs. (21 Nm).
     
    O 2 s sensor cable to the crossmember
     
    Union screw to the oil return line. Torque the screw to 21 ft. lbs. (28 Nm).
     
    Front propeller shaft. Torque the bolts to 47 ft. lbs. (64 Nm) and clip the vent line to the transmission.
     
    Rear heat shield
     
    Stabilizer bar. Torque the bolts to 16 ft. lbs. (22 Nm).
     
    Front heat shields
     
    O 2 s sensor connector
     
    Reinforcement plate
     
    Front splash guard
     
    Exhaust system
     
    Negative battery cable
     

  4.  
  5. Fill the transmission with the proper fluid to the proper level.
  6.  
  7. Start the vehicle and check for leaks, repair if necessary.
  8.  

4.4L (N62) & 4.8L Engines



  1. Drain the transmission fluid.
  2.  
  3. Remove the center muffler and catalytic converter.
  4.  
  5. Remove the front and rear heat shields.
  6.  
  7. Grip the clamping sleeve, slacken off the nut, detach the retainer towards the bottom using a suitable pry tool and pull the selector cable out of the holder.
  8.  
  9. Remove the driveshaft from the transmission. Tie the driveshaft up to one side.
  10.  
  11. Support the transmission with a suitable jack.
  12.  
  13. Remove the mounting bolts and remove transmission cross-member.

    Click image to see an enlarged view

    Fig. Location of the mounting bolts to remove the transmission crossmember (1)-4.4L (N62) & 4.8L Engines

  14.  
  15. Disconnect the electrical connectors from the servomotor.
  16.  
  17. Remove the transfer case mounting bolts.
  18.  
  19. Remove the transfer case.
  20.  
  21. Installation is the reverse order of removal. Tighten the transfer case mounting bolts to 32 ft. lbs. (43 Nm).
  22.  

 
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