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Home  ›  06 Bmw 525xi Transfer Case Service Kit?

06 Bmw 525xi Transfer Case Service Kit?

Written By Sunday, May 22, 2022 Add Comment Edit

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The following article gives detailed instructions on servicing the transfer case on a BMW E60 v series xDrive (all wheel bulldoze) car. Fifty-fifty though we have used a 2006 BMW 530xi to perform this service, this commodity can exist practical to any E60/E61 5 series xDrive vehicle with minor modifications.

The transfer case in your BMW xDrive (all bike drive) vehicle is an electronically actuated set of gears that controls how much ability is sent to the forepart and rear wheels. It is situated backside 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 transmission information technology is distributed to the front and rear differentials in a twoscore%/threescore% dissever, respectively. If the rear wheels start to lose traction, more ability is directed to the front so the driver can remain in control of the vehicle.

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

How to fill the transfer instance with new fluid

The normal process for filling the BMW E60 transfer example with new fluid is unfortunately a very difficult process. The fill plug is located on the upper right side of the transfer case above its mounting bracket. In order to properly remove the fill plug, showtime, the exhaust system must be lowered and the underlying heat shield removed. Next, the transfer example must be supported with a flooring jack while its mounting bracket is taken off. Then everything must exist put back together and torqued to the proper specifications to avoid future issues with the drivetrain.

Not only is removing the make full plug a complicated procedure for the seasoned technician working nether a hydraulic lift, merely information technology is likewise a nightmare for the home mechanic lying on their back underneath a car with very limited workspace.

Nosotros have ever been very adamant at the BMW Repair Guide in avoiding "shortcuts" when maintaining our vehicles unless following the normal procedure is not practical and a suitable alternative method exists. Attempting to disassemble the frazzle system and the transfer case mounting bracket to admission its fill plug is not a practical solution for the dwelling mechanic...at that place is an easier process that produces the same end result.

The BMW E60 transfer case tin can be easily refilled through the drain plug with an cheap fluid transfer pump and rubber stopper with a pigsty drilled in the middle of information technology. Refilling your transfer instance through the bleed plug is so simple, information technology turns a 3-4 60 minutes repair into a procedure that can be done in about 45 minutes. There are no brackets that demand to be removed...just empty the old fluid and refill the case through drain hole. The following video shows how to practice it. Please run across our Parts list beneath for a consummate inventory of what you will need to perform the drain plug refill too equally links to diverse tools throughout the steps.

Includes detailed office diagrams, part numbers and links to purchase all of the required components needed to consummate this repair.

Before starting this repair, y'all must have the following required parts.

All BMW all wheel drive models

Kit includes fill and bleed plugs. Service your xDrive transfer example with genuine BMW fluid and hardware to ensure peak operation and reliability.

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Department i - Draining the BMW E60 Transfer Example

Draining the transfer example in your BMW E60 v series is a relatively like shooting fish in a barrel procedure. You will need to jack and back up your vehicle on ramps or stands then you lot take enough room to get underneath the car. Call up...this is a messy job. We highly recommend performing this repair somewhere you don't mind getting muddied.

  1. Jack and back up your car at all four wheels using cycle ramps or stands. The BMW Repair Guide does not recommend using jack stands to support your vehicle unless the wheels demand to exist 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.
  2. Remove the engine (front) abdomen pan. The abdomen pan is held in place on the BMW E60 with phillips head screws.bmw e60 transfer case - Remove the engine belly pan
  3. Using an 8mm nut driver, remove the underfloor (rear) belly pan from the bottom of the motorcar.bmw e60 transfer case - Remove the underfloor belly pan
  4. Locate the transfer instance. Information technology is mounted to the rear of the manual in approximately the center of the vehicle.bmw e60 transfer case - Locate the vehicle's transfer case
  5. Locate the bleed plug located on the lower front of the transfer example.bmw e60 transfer case - Locate the transfer case drain plug
  6. The drain plug requires a 14mm hex socket for removal. Unfortunately, in that location is non enough clearance between the transmission oil pan and the transfer instance to get a standard 14mm hex socket into the plug (see paradigm below). The BMW Repair Guide recommends an easy shortcut to solve this problem...cut the cease off of a 14mm hex socket and apply a 14mm boxed end wrench to remove the plug. With a little help from a rubber mallet (the plug is usually torqued very tight), information technology volition quickly break gratis.A standard 14mm hex socket won't fit into the drain plug...it must be modified. bmw e60 transfer case - Modify a 14mm hex socket by cutting it as shown. bmw e60 transfer case - A modified 14mm hex socket...this will fit in drain plug. bmw e60 transfer case - Use a 14mm boxed end wrench to remove the drain plug.
  7. Remove the plug and allow the transfer case to thoroughly drain into a big plastic cup. Do no utilise a drain pan to capture the old fluid...you lot may want to reuse the fluid to exercise refiling the transfer case through the bleed hole (we know this sounds disruptive, and so delight see section ii beneath for more than information).Drain the old transfer case fluid into a plastic cup so you can practice refilling in section 2 below.

Section 2 - Refilling the BME E60 Transfer Case with New Fluid

As discussed at the get-go of this article, nosotros strongly feel that removing the exhaust and the mounting bracket to refill the transfer case is completely unnecessary. Refilling the transfer case through the drain hole is quick, like shooting fish in a barrel, and the best selection for the home mechanic. If this is your showtime time refilling the transfer case using this method, nosotros strongly recommend doing a exam run with the old fluid that was drained out in Section 1 - step 7 to a higher place. Over again, we encourage our readers to sentinel the post-obit video and review the beneath steps before starting the procedure.

  1. Before refilling the BMW E60 transfer case, you volition need to put together a simple device that will allow yous to pump fresh fluid in without it spilling out. This can be hands accomplished with an inexpensive condom stopper (1"x three/4" ten one") and a hand transfer pump. Past drilling a seven/sixteen" (11mm) hole in the centre of the rubber stopper with a paddle bit, the transfer pump hose tin be inserted securely into the transfer case without using the hard to access fill plug.bmw e60 transfer case - Hand transfer pump bmw e60 transfer case - #4 rubber stopper Use a 7/16
  2. The first pace is to drill a hole in the center of a prophylactic stopper. The rubber stopper should accept the post-obit approximate dimensions: 1" (tiptop width) x 3/iv" (bottom width) x 1" (total length).bmw e60 transfer case - Rubber stopper dimensions 1 bmw e60 transfer case - Rubber stopper dimensions 1 bmw e60 transfer case - Rubber stopper dimensions 1
  3. Using a 7/16" (11mm) paddle bit, carefully drill a pigsty direct through the center of the safe stopper. Attempt and continue the hole in the center of the stopper as best equally you can.bmw e60 transfer case - Drill a 7/16
  4. Insert the rubber stopper nearly one-half way into the transfer example drain hole. Yous want it slightly snug, but not too tight. If it is too tight you won't be able to insert the transfer pump tubing in the next stride.bmw e60 transfer case - Insert the rubber stopper into the drain hole.
  5. Cut off a half dozen" slice 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 rubber stopper.
  6. Attach the transfer pump to the tubing in the rubber stopper. Run another slice of tubing from the pump to a canteen of BMW DTF1 transfer case fluid (or if you are doing a test run...to the plastic cup of old fluid). If you take a helper bachelor (like this fine admirer in the image below), have them agree the bottle of transfer instance fluid so information technology doesn't tip over while you pump it.Only use BMW DTF1 transfer box oil in your E60 transfer case.
  7. Using slow and deliberate strokes, pump the entire 1 liter container of fluid into the transfer case. We recommend pumping the entire bottle into the case because a portion will be lost when removing the rubber stopper and reinstalling the new drain plug.bmw e60 transfer case - Pump the entire 1 liter bottle of fluid into the transfer case.
  8. When the transfer case is full of fluid, remove the pump and tubing from the condom stopper. Block the hole in the rubber stopper with your finger to go along fluid from escaping.
  9. In one quick motility, remove the rubber stopper from the drain hole and insert the drain plug. Put pressure on the bleed plug with two fingers while slowly turning it clockwise until it is snug. You will lose some fluid during this process but don't panic...since you pumped the entire i liter bottle in yous have plenty to spare. Technically the transfer box is suitably filled with one/two liter of fluid, then unless you lose more than fifty% of what you lot pumped in you lot are in proficient shape. Once once more, if you are nervous most this stride, do a trial run with the old fluid removed in Section ane. bmw e60 transfer case - Remove the rubber stopper and insert a new drain plug Use two fingers to put pressure on the drain plug while turning it clockwise.
  10. Using a torque wrench and a 14mm crows foot socket, torque the bleed plug to 60 Nm (44 ft-lb).bmw e60 transfer case - Use a 14mm crows foot to torque the drain plug bmw e60 transfer case - torque the drain plug to 60 Nm (44 ft-lb).
  11. You tin now reinstall the front and rear belly pans.

BMW E60 Transfer Example Service Finished

18-carat BMW Transfer Instance Command Unit of measurement

Part #: 27607599883

Part # 27-60-7-599-883 - Even if y'all maintain your BMW's four wheel bulldoze system as yous should, the electrical components that control its operation can fail. If your control unit of measurement has failed, replace information technology with this new unit of measurement from BMW and enjoy the sure-footed, all-atmospheric condition performance of 4 wheel drive over again. Fits: BMW E53 M54 iii.0L, BMW E53 N62 4.4L, BMW E53 N62 iv.8L, BMW E83

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Genuine BMW E30 Front Transfer Case Output Seal - Priced Each

Function #: 27241224660

Function # 27-24-1-224-660 - This rubber seal is oftentimes the cause of a leaking front transfer instance. It seals the junction where the output shafts enter the front transfer case. Priced each. Measurements: 44x60x10 Fits: BMW E30 325ix

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Baum Tools Transfer Case Bushing Tool

Office #: b221010plus

Used to remove and install transfer example mount bushings on X1, X3 and X5 vehicles. Fits: X1, X3, X5, X6, E53, E60, E61, E67, E70, E71, E83, E90, E91, E92 & RR1 chassis. Fits: BMW E53, BMW E60, BMW E61, BMW E70, BMW E71, BMW E83, BMW E90, BMW E91, BMW E92

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Assembled By ECS Transfer Case Service Kit

Part #: 27111226798kt

Often overlooked, your transfer case is a vital component in the all wheel drive system of your vehicle. If left unserviced, the fluid volition begin to pause downwards, leaving sludge and deposits to build upwardly throughout the transfer example. Equally the fluid breaks downward, lubrication backdrop are lost, assuasive excess vesture to take a toll on the internal components of the transfer case. Stay ahead of the game with a service kit from ECS Tuning. Kit includes: Replacement bleed and fill plugs 1 quart Redline D4 ATF Chapters: 1.1 pint Service tips: First, remove your fill plug, followed by the bleed plug. One time the fluid has drained completely, install the new drain plug and torque to specification. Using a fluid transfer pump, fill the transfer instance until the fluid begins to run freely from the fill hole. And then install the new make full plug and torque to specification. That'due south it! No filter to modify or gaskets to mess with! Bleed plug requires 15 lb/ft torque when tightening, The make full plug requires 24 lb/ft torque. ECS Tuning recommends servicing your transfer case every 60,000 miles. Fits: BMW E30 325ix

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Genuine BMW Hex Bolt - Priced Each

Part #: 26107542194

Part # 26-10-7-542-194 - These bolts are used to attach the universal flex disc (also known every bit a "giubo") to the transfer case. Priced each. Fits: BMW E60 525xi, BMW E60 528xi, BMW E60 530xi, BMW E60 535xi, BMW E61 530xi, BMW E61 535xi, BMW E90 325xi, BMW E90 330xi, BMW E90 328xi, BMW E90 335xi, BMW E91 325xi, BMW E91 328xi, BMW E92 328xi, BMW E92 335xi, BMW E84 X1 xDrive28i, BMW E84 X1 xDrive35i

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Schwaben Transfer Case Bushing Tool

Role #: lcb202sch

This comprehensive tool kit includes adapters and other pieces needed for removal and reinstallation of a transfer case mount. Allows for like shooting fish in a barrel installation with the transfer instance mounted on the vehicle factoring in the space constraints that exist. Used to remove and install transfer example mount bushings on X1, X3 and X5 vehicles. Fits: X1, X3, X5, X6, E53, E60, E61, E67, E70, E71, E83, E90, E91, E92 & RR1 chassis. Fits: BMW E53, BMW E60, BMW E61, BMW E70, BMW E71, BMW E83, BMW E90, BMW E91, BMW E92

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Corteco Transfer Case Output Shaft Seal

Role #: 27107546667

This rubber seal is ofttimes the cause of a leaking transfer case. It seals the junction where the output shafts enter the front transfer case. Priced each. Measurements: 52x78x8 Fits: BMW E60 525xi, BMW E60 528xi, BMW E60 530xi, BMW E60 535xi, BMW E61 530xi, BMW E61 535xi, BMW E70 X5 M, BMW E70 X5 xDrive30i, BMW E70 X5 xDrive35d, BMW E70 X5 xDrive35i, BMW E70 X5 xDrive48i, BMW E70 X5 xDrive50i, BMW E71 X6 35iX, BMW E71 X6 50iX, BMW E71 X6 M, BMW E71 X6 xDrive35i, BMW E71 X6 xDrive50i, BMW E90 325xi, BMW E90 330xi, BMW E90 328xi, BMW E90 335xi, BMW E91 325xi, BMW E91 328xi, BMW F01 750i xDrive, BMW F01 Alpina B7, BMW F02 750Li xDrive, BMW F02 750LiX, BMW F02 740Ld xDrive, BMW F02 740Li xDrive, BMW F07 535i xDrive, BMW F07 550i xDrive, BMW F10 535i xDrive, BMW F10 550i xDrive, BMW F10 528i xDrive, BMW F10 535d xDrive, BMW F25 xDrive2.8i, BMW F25 xDrive3.5i, BMW F25 X3 xDrive28d, BMW F12 650iX, BMW F12 640i xDrive, BMW F13 650iX, BMW F13 640i xDrive, BMW F30 320i xDrive, BMW F30 328i xDrive, BMW F30 328d xDrive, BMW F30 335i xDrive, BMW F30 340i xDrive, BMW E84 X1 xDrive28i, BMW E84 X1 xDrive35i, BMW F32 428i xDrive, BMW F32 435i xDrive, BMW F31 328i xDrive, BMW F31 328d xDrive, BMW F34 328i xDrive, BMW F34 335i xDrive, BMW F22 228i xDrive, BMW F22 M235i xDrive, BMW F06 640i xDrive, BMW F06 650i xDrive, BMW F06 Alpina B6 xDrive, BMW F15 X5 xDrive35d, BMW F15 X5 xDrive35i, BMW F15 X5 xDrive50i, BMW F16 X6 xDrive35i, BMW F16 X6 xDrive50i, BMW F36 428i xDrive, BMW F36 435i xDrive, BMW F33 428i xDrive, BMW F33 435i xDrive, BMW F26 X4 xDrive28i, BMW F26 X4 xDrive35i, BMW F23 228i xDrive, BMW F23 M235i xDrive, BMW F85 X5 M, BMW F86 X6 M

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Genuine BMW Transfer Case Resistor

Part #: 27107557345

Part # 27-10-7-557-345 - This resistor is located on the transfer case actuator and can cause the actuator to non piece of work properly if it were to fail. Fits: BMW E53, BMW E60 525xi, BMW E60 528xi, BMW E60 530xi, BMW E60 535xi, BMW E61 530xi, BMW E61 535xi, BMW E83, BMW E90 325xi, BMW E90 330xi, BMW E90 328xi, BMW E90 335xi, BMW E91 325xi, BMW E91 328xi, BMW E92 328xi, BMW E92 335xi

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Genuine BMW Front end Output Shaft

Part #: 27107548115

Part # 27-10-vii-548-115 - If the front output shaft on your BMW has failed, supercede information technology with this Original BMW part to become back on the road again. Don't forget to replace the seal! Fits: BMW E60 525xi, BMW E60 528xi, BMW E60 530xi, BMW E60 535xi, BMW E61 530xi, BMW E61 535xi, BMW E90 325xi, BMW E90 330xi, BMW E90 328xi, BMW E90 335xi, BMW E91 325xi, BMW E91 328xi, BMW E92 328xi, BMW E92 335xi

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Genuine BMW Transfer Case Control Unit of measurement

Part #: 27607607980

Part # 27-threescore-seven-607-980 - Fifty-fifty if you maintain your BMW'due south iv wheel drive organization as you should, the electric components that command its operation can neglect. If your control unit has failed, replace it with this new unit from BMW and relish the sure-footed, all-weather performance of 4 wheel drive again. Fits: BMW E60 525xi, BMW E60 528xi, BMW E60 530xi, BMW E60 535xi, BMW E61 530xi, BMW E61 535xi, BMW E90 325xi, BMW E90 330xi, BMW E90 328xi, BMW E90 335xi, BMW E91 325xi, BMW E91 328xi, BMW E92 328xi, BMW E92 335xi

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Dorman Drive Shaft Assembly - Front

Function #: 936-311

The drive shaft in your vehicle transmits the power to the wheels. Frequently, they can feel harm due to their vulnerable mounting location under the car. Spinning at such fast speeds, even the littlest bit of unbalance tin can be exploited. This causes serious vibrations and can eventually lead to other driveline component failure. Supplant your drive shaft if it has been damaged or thrown out of balance with this quality Dorman office from ECS Tuning. With the proper length and correct ends, information technology's the perfect piece to eliminate that vibration and keep your wheels spinning smoothly. Dorman is a high quality OE parts supplier that focuses on providing extremely reliable parts that will not simply terminal as long every bit your stock part, but oft times addresses common problems and improves upon the design to extend the parts life. Fits: BMW E60 525xi N52 3.0L, BMW E60 528xi N52 iii.0L, BMW E60 530xi N52 3.0L, BMW E60 535xi N54 iii.0L, BMW E61 530xi N52 3.0L, BMW E61 535xi N54 iii.0L

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Genuine BMW Seal - Transfer Case Output Shaft

Part #: 27107539266

Office # 27-ten-vii-539-266 - Fits: BMW E53 X5 M54 iii.0L, BMW E53 X5 N62 four.4L, BMW E53 X5 N62 4.8L, BMW E60 525xi N52 3.0L, BMW E60 528xi N52 three.0L, BMW E60 530xi N52 3.0L, BMW E60 535xi N54 3.0L, BMW E61 530xi N52 three.0L, BMW E61 535xi N54 3.0L, BMW E70 X5 M S63 four.4L, BMW E70 X5 xDrive30i N52 3.0L, BMW E70 X5 xDrive35d M57 3.0L, BMW E70 X5 xDrive35i N55 3.0L, BMW E70 X5 xDrive48i N62 iv.8L, BMW E70 X5 xDrive50i N63 4.4L, BMW E71 X6 M S63 four.4L, BMW E71 X6 xDrive35i N54 3.0L, BMW E71 X6 xDrive35i N55 three.0L, BMW E71 X6 xDrive50i N63 4.4L, BMW E83 X3 M54 2.5L, BMW E83 X3 M54 3.0L, BMW E90 325xi N52 3.0L, BMW E90 330xi N52 iii.0L, BMW E90 328xi N52 3.0L, BMW E90 335xi N54 iii.0L, BMW E90 335xi N55 3.0L, BMW E91 325xi N52 three.0L, BMW E91 328xi N52 3.0L, BMW E92 328xi N52 3.0L, BMW E92 335xi N54 3.0L, BMW E92 335xi N55 3.0L, BMW F01 750i xDrive N63 4.4L, BMW F02 750Li xDrive N63 4.4L, BMW F02 740Ld xDrive N57 3.0L, BMW F02 740Li xDrive N55 3.0L, BMW F10 535i xDrive N55 3.0L, BMW F10 550i xDrive N63 4.4L, BMW F10 528i xDrive N20 ii.0L, BMW F10 535d xDrive N57 iii.0L, BMW F12 650iX N63 4.4L, BMW F12 640i xDrive N55 3.0L, BMW F13 650iX N63 four.4L, BMW F13 640i xDrive N55 3.0L, BMW F30 320i xDrive N20 two.0L, BMW F30 328i xDrive N20 2.0L, BMW F30 328d xDrive N47 2.0L, BMW F30 335i xDrive N55 3.0L, BMW F30 340i xDrive B58 3.0L, BMW F30 330i xDrive B48 ii.0L, BMW E84 X1 xDrive28i N20 ii.0L, BMW E84 X1 xDrive35i N55 3.0L, BMW F32 428i xDrive N20 two.0L, BMW F32 435i xDrive N55 3.0L, BMW F32 440i xDrive B58 three.0L, BMW F32 430i xDrive B46 2.0L, BMW F31 328i xDrive N20 2.0L, BMW F31 328d xDrive N47 two.0L, BMW F22 M240i xDrive B58 3.0L, BMW F22 230i xDrive B46 2.0L, BMW F33 428i xDrive N20 2.0L, BMW F33 435i xDrive N55 iii.0L, BMW F33 440i xDrive B58 three.0L, BMW F33 430i xDrive B46 2.0L, BMW F23 M240i xDrive B58 3.0L, BMW F23 230i xDrive B46 2.0L

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06 Bmw 525xi Transfer Case Service Kit?,

Source: https://bmwrepairguide.com/bmw-e60-transfer-case-service-2004-2010-5-series-xdrive-awd/

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