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      07-27-2017, 05:12 PM   #1
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Transfer Case Failures Database

I was curious about all the transfer case failures, and the claim of correlation between them and factory staggered tires setup, so I did a quick search through here and another forum for F3x transfer case issues. Thus far I've found 28 instances.

You can see the what I've found in this Google spread sheet.

Please feel free to add missing info, or your incident, if not listed.

So far, I don't think there's enough conclusive data to link staggered setups to the transfer case failures.

Last edited by FaRKle!; 07-27-2017 at 05:30 PM..
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      07-27-2017, 07:05 PM   #2
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Quote:
Originally Posted by FaRKle! View Post
I was curious about all the transfer case failures, and the claim of correlation between them and factory staggered tires setup, so I did a quick search through here and another forum for F3x transfer case issues. Thus far I've found 28 instances.

You can see the what I've found in this Google spread sheet.

Please feel free to add missing info, or your incident, if not listed.

So far, I don't think there's enough conclusive data to link staggered setups to the transfer case failures.
wow, good job!

i should get mine checked out before my warranty is up.
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      07-27-2017, 08:26 PM   #3
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Quote:
Originally Posted by Johnny250 View Post
wow, good job!

i should get mine checked out before my warranty is up.
Median failure mileage is 43.5k and average is a bit lower at 40.75k

Based upon that, I'm wondering if having the transfer case fluid replaced (say at 30k) helps prevent the failure, or if the failure mode isn't related to the fluid at all.
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      07-27-2017, 08:28 PM   #4
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Quote:
Originally Posted by Johnny250 View Post
Quote:
Originally Posted by FaRKle! View Post
I was curious about all the transfer case failures, and the claim of correlation between them and factory staggered tires setup, so I did a quick search through here and another forum for F3x transfer case issues. Thus far I've found 28 instances.

You can see the what I've found in this Google spread sheet.

Please feel free to add missing info, or your incident, if not listed.

So far, I don't think there's enough conclusive data to link staggered setups to the transfer case failures.
wow, good job!

i should get mine checked out before my warranty is up.
So how do you go about getting this checked? Is this something the dealership is aware of and be able to diagnose premature failure??
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      07-29-2017, 03:42 AM   #5
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Mines is a 420d...

Anyone had it fixed?? Was it just fluid top up or full replacement?
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      08-15-2017, 07:59 PM   #6
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I just got my 3rd transfer case @ 119,xxx miles. Counting the one on it when i bought it new, that's 4 in 120k miles...Each time it completely fails, blows up or whatever and the car is undriveable.
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      08-16-2017, 11:20 AM   #7
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This should be a sticky
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      08-23-2017, 05:50 PM   #8
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Hello! I recently buyed a 435 i xdrive with mppk. Iove the car but something is boddering me: when in strog acceleration the car seems to hesitate a lots off times and i see the power comming down, in the sport screen, when.this occurs. My bmw.dealler.says is transfer box, he don't have any code error but when he turn ir off the problem stops.. i am wating for.the repair price. It's sad, the car as only 50000km's.
Anyone have an ideia off something else causing the symptoms?
Thank you very much!!
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      10-10-2017, 10:43 AM   #9
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I'm adding myself to the list, my 328D transfer case failed 3 days after I bought the used car.
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      10-10-2017, 12:11 PM   #10
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Quote:
Originally Posted by Andrew@FixMyVW View Post
I'm adding myself to the list, my 328D transfer case failed 3 days after I bought the used car.
Thanks for adding your info! I hope your repair gets covered by the seller!
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      10-10-2017, 12:25 PM   #11
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Quote:
Originally Posted by FaRKle! View Post
I was curious about all the transfer case failures, and the claim of correlation between them and factory staggered tires setup, so I did a quick search through here and another forum for F3x transfer case issues. Thus far I've found 28 instances.

You can see the what I've found in this Google spread sheet.

Please feel free to add missing info, or your incident, if not listed.

So far, I don't think there's enough conclusive data to link staggered setups to the transfer case failures.
Mines on there and looks good. Nice database! Not sure what your trying to figure out but hopefully new owners can get an idea of if/when they go out. I saw a thread of one getting rebuilt too. Good to see this is getting the spotlight, when mine went out it was hard to find others. Now seems its coming into the light. Good Stuff!
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      10-11-2017, 10:15 AM   #12
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Have a '13 328ix purchased as a CPO with 37k miles. Hesitation / slip started around 51k and got progressively worse on acceleration. Originally thought it may be a fouled plug or universal joint but no codes ever were thrown. Had the Dealer look at the problem and replaced the transfer case at 53k miles. Good thing it was under warranty (whew). $3k plus repair cost.
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      10-17-2017, 10:55 PM   #13
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great write up.

my advice to potential buyers is to get an extended warranty if possible. good thing i purchased one when i got the car. the total bill for the repair was $6500
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      05-15-2018, 10:45 AM   #14
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our '15 328d Wagon is going in today for this issue I believe. The foreman went on a test drive with me and thinks either carbon build up or Transfer Case (most likely the latter since there are no drivetrain malfunctions/CELs). They will unplug the transfer case and see if the issue still happens to determine if it's the Transfer Case.
Car is still under warranty fortunately!
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      07-01-2018, 01:21 PM   #15
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Honestly, I wonder if this is a software issue.

The front diff is a full time locked differential, with the slip for wheel differential (for turns) happening inside the transfer case. The clutches happen to be very strong inside the transfer case, and if the transfer case actuator is programmed to be aggressive, the extra differential speed may be putting stress on the output flange.
I have a close contact at BMW engineering and I will ask him to see what he can find out as well.

I find the ATC35L a robust transfer case with good build. Especially when compared with old transfer cases with plastic gears and things.
I wonder if running it in 2wd mode (coding or disabling things) is protective to the flange.

I am at 79,700 miles, original 27107505374 case built Sept 20th, 2013. My last 9000 miles have been using strictly rear wheel drive only, through disabling the VTG module, and tuned with more power.


I was preparing to start my own thread for analysis... but there is no reason, now that I was directed to this thread.

This is what I was going to post to try to prove my hypothesis:
Use for ideas if nothing else.





_________________________________________________




If you have a 4wd BMW with the ATC35L transfer case, I invite you to participate in this data collection.

*It is important to have documentation of transfer case failures, as well as data on cars without transfer case failures, for a control group*



Data Collection
Having very accurate data is critical to sorting out clues as to what may be causing the failures. I ask that you post in the following format, for each transfer case failure event, or if no failure in your F3x, then fill out information about your car.

A. Basic Car Info
  1. Car Year and Model:
  2. Last 7 of VIN *(needed to check car options/production date, can be sent by PM if desired):
  3. Current Mileage:
  4. Total Miles owned:
  5. Sports Automatic Transmission Software ("2TB" option, or retrofit): Y/N
  6. Known software updates to car:
  7. Current I-Level (if known):
  8. List any Maintenance to Driveline (oil changes, etc):
  9. List Mods Done to Vehicle (Extra power, different size wheels, etc):
B. Driving Habits/Conditions
  1. Driving Mode Used Mostly: (ECO PRO, Comfort, Sport, Sport+)
  2. Driving Style: (Relaxed, Moderate, Aggressive, Racecar)
  3. Automatic Gear Shifting or "Manual":
  4. Type of Driving: (Highway, city, mixed?)
  5. Describe the terrain/landscape it is driven in:
  6. Any Towing with the car:
C. Transfer Case Failure
Number of Known Transfer Case Failures: (for each failure, describe below, separately. If 0 failures (control group), please skip below.)
  1. Mileage at failure:
  2. Component That Failed: (if known)
  3. Method of Repair: (dealer, privately. Replaced transfer case, or just output flange?)
  4. Part number/date of manufacture of faulty transfer case: (if known)
  5. Part number of replacement transfer case:


If you have had multiple failures for the same car, please list each separately!

Please add any other information that you consider relevant with great detail.




If you have had NO transfer case failures on your F3x, please fill this out as well, for data control and comparison. Control data is just as important!
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Last edited by Enabled; 07-01-2018 at 01:28 PM..
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      08-06-2018, 03:28 PM   #16
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Quote:
Originally Posted by FaRKle! View Post
I was curious about all the transfer case failures, and the claim of correlation between them and factory staggered tires setup, so I did a quick search through here and another forum for F3x transfer case issues. Thus far I've found 28 instances.

You can see the what I've found in this Google spread sheet.

Please feel free to add missing info, or your incident, if not listed.

So far, I don't think there's enough conclusive data to link staggered setups to the transfer case failures.
The 335d one is incorrect, it turned out to just be a rubber bush at fault! Read post #29:

https://f30.bimmerpost.com/forums/sh...er+case&page=2
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      08-06-2018, 07:18 PM   #17
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Mine failed at 55k miles 2014 335xi stick.
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      08-09-2018, 06:29 PM   #18
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My 2014 328d x drive wagon's transfer case just crapped out at 81,000 miles. It sputtered a bit but I thought it was an EGR issue or something. Driving in town it just totally failed. Dealer reported the today its a $7000 repair. New 27107649725 Transfer Case Assembly required. Dealer said I abused it. I have been accused of driving like an old lady. I took this very hard as I have done nothing of the sort. Having joined this forum today I have read all the posts and there are lots of these failures contrary to what the dealer told me. Thank you everyone for sharing this information. I have also added myself to the spreadsheet. Now, what do I do? Buy the $5400 part and have BMW install it? Buy an OE part new on eBay and have them install it, (no warranty). Take it to someone else (BMW guy) and have them install it? Please help. I am still paying for the car.
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      08-09-2018, 06:50 PM   #19
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The other part number 27108643149 is currently $700 brand new from dealer, discounted in the last few months from $5000. Neither one is clearly better than the other.

It comes with new module, and without the mounting bushing. Breather hose needs to be transferred from yours, and then make sure it has oil.
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      08-10-2018, 05:01 PM   #20
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Quote:
Originally Posted by Enabled View Post
The other part number 27108643149 is currently $700 brand new from dealer, discounted in the last few months from $5000. Neither one is clearly better than the other.

It comes with new module, and without the mounting bushing. Breather hose needs to be transferred from yours, and then make sure it has oil.
so the only part that needs to be replaced is this?

https://www.getbmwparts.com/oem-part...5l-27108643149

the 7k dealers are charging.. they're pretty much charging 6k for labor?
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      08-10-2018, 06:24 PM   #21
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They have 2 choices for transfer case.

https://www.realoem.com/bmw/enUS/sho...diagId=27_0065

27108643149 recently reduced to $700 from $4-5k (likely as a good faith initiative)

or

27107649725 not reduced (yet?)




You would also need a new mounting bushing, oil, and you should put in new flex disk.


No it does not cost $6000 in labor.



Alternatively you can replace just the sheared output flange (that's the part that generally fails, for whatever unknown reason) for about $300 plus labor. It may be possible to do on car with driveshaft removed.
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      08-10-2018, 06:36 PM   #22
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Quote:
Originally Posted by Enabled View Post
They have 2 choices for transfer case.

https://www.realoem.com/bmw/enUS/sho...diagId=27_0065

27108643149 recently reduced to $700 from $4-5k (likely as a good faith initiative)

or

27107649725 not reduced (yet?)




You would also need a new mounting bushing, oil, and you should put in new flex disk.


No it does not cost $6000 in labor.



Alternatively you can replace just the sheared output flange (that's the part that generally fails, for whatever unknown reason) for about $300 plus labor. It may be possible to do on car with driveshaft removed.
https://www.getbmwparts.com/oem-part...5l-27107649725

it's been reduced also.

Could this be the beginning of a 2k job at the dealership?
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