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Small update, I finally got to cleaning the original flange, and I am convinced it is from vibration.

Take a look at the spline wear:












In the mean time, I bought a spare gas BMW V8 transfer case with 49k miles... It had very very fine play in the flange, but not from wear, which was interesting. The flange and shaft is perfect after that many miles. This suggests that it is a vibration factor, along with the flange not being pressed on. The fine movement from not being pressed, plus vibration grows into eventual damage.

See the pictures:

[swissarmyknife]

Finally getting my local shop to apply the loctite and replace the joint with the updated version. I will provide the needed parts, they do the laber at ~450 for the complete job. Also have them do a transmission flush.

I now got 108k miles on it, so 5k extra since we bought it in Oct 2019. So far had not felt any vibrations. Then I'll finally get the Karma tune.

[dreaming.haze]

Just got through the Flange + Loctite 648 + Rubber Guibo. Job itself went smooth. The slight slip when getting off the line is decreased / eliminated from testing so far. Old flange looked like it was still in semi-decent shape, but went with a new one as it was on hand and the car has 71k miles. Pictures:

Old Flange


New Flange

[Enabled]

Originally Posted by dreaming.haze

Just got through the Flange + Loctite 648 + Rubber Guibo. Job itself went smooth. The slight slip when getting off the line is decreased / eliminated from testing so far. Old flange looked like it was still in semi-decent shape, but went with a new one as it was on hand and the car has 71k miles. Pictures:

Old Flange


New Flange

Google doesn't support hot linking for pictures, can you upload somewhere else. I'm curious what it looks like.

[dreaming.haze]

Enabled Here we are:

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Yours was in good shape.
New output flange plus semi-permanent fixation likely saved you a lot of money. I don't think it will give you any trouble.





For what it's worth, the output flange on X3/X5 transfer case (ATC 45L) seems to be pressed on. We got a spare for my dad's X3 28d and the used spare flange couldn't be easily removed by hand.
So have there been any failed flanges on X3 28d and X3 28i?

[EricD735i]

Originally Posted by Enabled

For what it's worth, the output flange on X3/X5 transfer case (ATC 45L) seems to be pressed on.

Good to know. I was going to check the flange in my wife’s X3 once things warm up here, would you say not worth the bother?

[Enabled]

Originally Posted by EricD735i

Good to know. I was going to check the flange in my wife’s X3 once things warm up here, would you say not worth the bother?

This was my dad's interpretation, as he was the one who attempted to pull it off. I wanted to see it for myself before finalizing conclusions.

It was so inexpensive and confirmed ultra-low miles that I had to have gotten it.

[swissarmyknife]

Picking up my car today after the spline was 'superglued' together with high strength Loctite. Asked the shop to take pics (though have not seen them) of the spline and if the spline was in bad shape to start a warranty claim with my extended warranty. After talking to he owner over the phone, the play was marginal and the mechanic said that the Loctite will do it's job. I guess only time will tell.

BTW. This is the original output shaft now with about 108k miles on it.

[johnung]

Originally Posted by Enabled

This was my dad's interpretation, as he was the one who attempted to pull it off. I wanted to see it for myself before finalizing conclusions.

It was so inexpensive and confirmed ultra-low miles that I had to have gotten it.

Is there any other transfer case part to check or replace during a transfer case fluid change, as preventative maintenance in a car with a 6-cylinder engine?

My understanding from reading through is that the focus of these transfer case issues has been the vibration in the 4-cylinder engine.

I'm about to suction and refill the transfer case fluid on my 2015 335i xDrive with 37k miles. I understand that the N55 6-cylinder engine shouldn't have the same vibration issues. But is there any other part that should be checked or changed at the same time.

Does Shell make the transfer case fluid for BMW so that buying the cheaper Shell brand is the exact same thing?
Thanks!

[Enabled]

Originally Posted by johnung

Is there any other transfer case part to check or replace during a transfer case fluid change, as preventative maintenance in a car with a 6-cylinder engine?

My understanding from reading through is that the focus of these transfer case issues has been the vibration in the 4-cylinder engine.

I'm about to suction and refill the transfer case fluid on my 2015 335i xDrive with 37k miles. I understand that the N55 6-cylinder engine shouldn't have the same vibration issues. But is there any other part that should be checked or changed at the same time.

Does Shell make the transfer case fluid for BMW so that buying the cheaper Shell brand is the exact same thing?
Thanks!

You should convert to the rubber giubo (flex disk) because of known cracking and damage from the aluminum one (if so equipped). Otherwise there isn't much else you can check. The 6-cyl doesn't seem to have damage from the vibrations, but since it's the same exact transfer case, it wouldn't hurt to loctite it anyways.

I used the expensive BMW fluid, unfortunately, on my first transfer case fluid change.

[Enabled]

Originally Posted by swissarmyknife

Picking up my car today after the spline was 'superglued' together with high strength Loctite. Asked the shop to take pics (though have not seen them) of the spline and if the spline was in bad shape to start a warranty claim with my extended warranty. After talking to he owner over the phone, the play was marginal and the mechanic said that the Loctite will do it's job. I guess only time will tell.

BTW. This is the original output shaft now with about 108k miles on it.

In for pics! That's important

[swissarmyknife]

Originally Posted by Enabled

In for pics! That's important

Well, they didn't take pics and primarily because the shop owner said that the output spline looked in very good condition. Was a little perturbed about that but I know he does excellent work, so not worried about the outcome. Also, later confirmed that if the spline was beyond the Loctite he would have called the aftermarket warranty and to tell them the customer brought the car in with vibrations from the drive shaft to make it appear like there was a pre-existing issue that warranted to look into the problem. He was going to do that without me prompting him to.

He also said that the original flex coupling was still installed, the one that was superseded, so could it be that this was still the original TC at 108k on it?

At the end the flex coupling and the TC rear coupling were replaced and the TC rear coupling Loctite'ed to the TC output spline.

Today I ordered the Kerma tune

[dreaming.haze]

Looks like we might finally be seeing a recall for the output flange. Note recall SIB 270120.

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It looks like they'll be replacing the output flange mostly? (not sure why it's being called a CV joint...)

I am very curious if they will have a press fit part, or glue it on as here?

[dreaming.haze]

Agreed on the strange wording. I would say their focus will be on the output flange. Then if the aluminum shelled guibo is still on the car it would be replaced with a rubber one hopefully.

Just got finished up with the fix - so I'll wait for others to have the fix performed and report back over what actual change they perform.

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I will try to get more info from inside sources in the coming week. Currently that's all that is known. At least no mileage specified, yet.

[Enabled]

From some communication:

Flange will be replaced. Not sure if they replace all, or just ones showing wear. If it has spun, transfer case will be replaced.
If there is an aluminum giubo on car still, it will be replaced with the rubber one.
No details on mileage limits or anything, yet.

No other details yet.

[Tim07e90]

Originally Posted by Enabled

From some communication:

Flange will be replaced. Not sure if they replace all, or just ones showing wear. If it has spun, transfer case will be replaced.
If there is an aluminum giubo on car still, it will be replaced with the rubber one.
No details on mileage limits or anything, yet.

No other details yet.

I wonder if they give me money back if I had to replace a whole transfer case. I'm sure due to the guibo issue.

[Enabled]

Originally Posted by Tim07e90

I wonder if they give me money back if I had to replace a whole transfer case. I'm sure due to the guibo issue.

If they did, it would be done through www.bmw-rp.com
Keep your receipts. Corporate is barely getting info on this, so it will be a while given the world situation. Recall parts are not allocated nor available yet.

[Tim07e90]

Originally Posted by Enabled

If they did, it would be done through www.bmw-rp.com
Keep your receipts. Corporate is barely getting info on this, so it will be a while given the world situation. Recall parts are not allocated nor available yet.

Good to know. Yes, I've kept my BMW dealership invoice and receipt from it since I used a credit card. Thanks Enabled

[Pittcrew]

Does this cover gas models as well?
Shame if it's only diesels.