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2010 2011 BMW 5 Series Forum F10 BMW 5-Series (F10) Forums F10 / F11 5-Series Photos - Video - Media transfer case replacement
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      06-08-2018, 03:48 PM   #1
David3
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transfer case replacement

Well, I get to replace my transfer case on my '12 550i Xdrive. The issue started as a 0% throttle whine. Ultimately progressed to fairly significant drive train bucking mostly at 0% throttle but also during spirited acceleration. So, wanting to do this myself, but information on line is scarce. And, it seems that both the ACT 350 and 35L are listed as a fit for my model/year. The ACT 35L seems both more plentiful and cheaper.

My question is whether or not the ACT 35L is the updated and proper transfer case model? Anyone ever replaced the transfer case on an F10?

BTW, I disconnected (power/controls) the transfer case control module and the noise and bucking are gone...except for very spirited acceleration. Of course I get a slew of warning lights: ABS, 4x4, parking brake, and adaptive cruise does not work...all to be expected.
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      06-12-2018, 10:36 AM   #2
David3
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Update: Dealer says part number should be 27.10.7.649.725. ACT 35L. My cost is $602.58 + $1083 refundable core charge.

Guess I will go ahead and get it changed out...not looking forward to the task.

Any other parts I will need?

Last edited by David3; 06-13-2018 at 02:13 PM..
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      07-09-2019, 03:00 PM   #3
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Second update: Part cost is way higher now. My new cost is $1920 + core. So, I decided to rebuild the unit myself. I opened it up over the weekend and it looked very good inside. The bearings seemed very smooth without any noticeable excess movement. The output flange splines seem worn and thus loose. I plan to use loctite 660 on the flange splines upon reassembly. I have ordered a clutch pack kit for $311 (including expedited shipping) and will install upon arrival (Wednesday). The existing clutch disks and steels looked okay, but I don't know how much material the discs had when new. The steels looked a little discolored, but not blued. And, I ordered a rubber guibo to replace the original aluminum version that I suspect contributes to the spline wear. BMW TIS demands that the rubber guibo be used upon reassembly.

I will update again after the unit back together and in the car.
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      07-17-2021, 07:49 AM   #4
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Quote:
Originally Posted by David3 View Post
Second update: Part cost is way higher now. My new cost is $1920 + core. So, I decided to rebuild the unit myself. I opened it up over the weekend and it looked very good inside. The bearings seemed very smooth without any noticeable excess movement. The output flange splines seem worn and thus loose. I plan to use loctite 660 on the flange splines upon reassembly. I have ordered a clutch pack kit for $311 (including expedited shipping) and will install upon arrival (Wednesday). The existing clutch disks and steels looked okay, but I don't know how much material the discs had when new. The steels looked a little discolored, but not blued. And, I ordered a rubber guibo to replace the original aluminum version that I suspect contributes to the spline wear. BMW TIS demands that the rubber guibo be used upon reassembly.

I will update again after the unit back together and in the car.
Did you end up getting the unit rebuilt? I have a 535 with output shaft bearing noise. I pinpointed it on a lift last night. I'm weighing options between buying a used transfer case and rebuilding this one. I found a European website "awd.tech" that sells all the parts for the ATC-350 in my car. I'm thinking bearings, seals and clutch pack.

Two further questions - 1) is there any reprogramming needed when swapping units/replacing clutch packs? 2)were you able to remove the transfer case without dropping the whole trans? I assume the exhaust needs to come out, disconnect the driveshafts, crossmember(s), lower back end of the assembly. Just wondering if there's room to reach all the connecting bolts.
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      07-17-2021, 10:32 AM   #5
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How many miles do you have on your car? I'm at 109,000 and I'm thinking of changing the fluid as preventative maintenance.
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      07-25-2021, 02:39 PM   #6
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I'm really surprised!!
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      09-28-2021, 11:33 PM   #7
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What happened to David3? He left us hanging.

Ed
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      09-29-2021, 02:14 PM   #8
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Quote:
Originally Posted by hurst01 View Post
What happened to David3? He left us hanging.

Ed
He hasn't been at this site since last November...
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      10-16-2021, 10:10 AM   #9
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Quote:
Originally Posted by culto View Post
How many miles do you have on your car? I'm at 109,000 and I'm thinking of changing the fluid as preventative maintenance.
There are several of us that have changed out our fluids. I would not hesitate to do it again. My car is at almost 140k, and without problems, knock on wood!
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      10-20-2021, 06:38 PM   #10
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At what miles transfer case needs replacement?
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      02-06-2022, 10:01 AM   #11
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I had a lot of problems with my xdrive, changed all tires and one rim and problems where gone.
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      02-17-2022, 07:59 PM   #12
David3
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Sorry I disappeared…focused on other things. I never fixed the transfer case. New fluid and discs made it better for a short time only. I ended up electronically disconnecting the transfer case which solved the noise drivability issues…but just carrying dead weight.

I am ready to fix it now. Looking for replacement transfer case
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      02-18-2022, 08:56 AM   #13
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BMW can't seem to do a lot of things correctly..add simple 4x4 transfer case to the list.
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      04-11-2022, 08:06 AM   #14
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Quote:
Originally Posted by David3 View Post
Sorry I disappeared…focused on other things. I never fixed the transfer case. New fluid and discs made it better for a short time only. I ended up electronically disconnecting the transfer case which solved the noise drivability issues…but just carrying dead weight.

I am ready to fix it now. Looking for replacement transfer case
I just fixed this problem a few months back. I got a replacement ATC 35L and actuator module. Then had it programmed in ISTA.
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