2004 X3 Clunking noise braking (transfer case ?)

[ryster]

Hi,

I am having an issue with a 2004 X3 E83 which it clunks while braking at low speeds/corners.

RECENT HISTORY ON THE CAR currently 195k.
January - Brake, ABS, 4X4 Lights came on (issue with transfer case)
March - Changed new actuator motor disc only (fixed the issue)
May - Clunking noise discovered while braking at low speeds.

I have taken it into a mechanic and they have advised me I have to change the whole transfer case costing 3k.

I hear there could be a few other reasons why this happens and I may not have to change the whole transfer case as suggested..

Tyres are 1mm on fronts (needs replacing), 2mm rears

Could the tyres be the issue ? or does it simply need an transfer oil change as this hasn't been done ?, Possible belt change ?

[91e34M5]

If the tires are not all the same diameter, then that can cause binding in the transfer case. A good example where this can happen is when someone replaces only two tires. It can also happen if the tires are not properly rotated during the life of the tire. I can't see that changing the fluid would reduce or eliminate the clunking.

[dallanz]

Slightly off the subject but replaced front tyres today on 2005 X3 and now have a clunk when braking and also a judder when accelerating around 2000 revs. after googling diff issues it seems its a common issue on the earlier X3 that different tyres front and back can cause diff issues. Ive ordered 2 more tyres for the rear which are being fitted tomorrow as in lots of cases on line this has solved the judder? Would anybody know anything similar happening

[91e34M5]

Good thing to order tires so they will all match in diameter. This is likely the cause of your issues. However, check and make damn sure that your lug bolts are tight.

[ryster]

Update:

Have changed the tyres to 4 new ones same thread as before (however not star rated). Has made the clunk less noticable, however 3 weeks in noticed the 4x4 light came on and is still on, clunking is getting worse, I hear a click noise coming near the transfer case when turning the car off.. Is it worth doing a fluid change as I've heard this may rectify it?? or could it be the actuator gear faulty again after 6months of being replaced ?? Or is it something else ?? Thoughts ?

[91e34M5]

Update:

Have changed the tyres to 4 new ones same thread as before (however not star rated). Has made the clunk less noticable, however 3 weeks in noticed the 4x4 light came on and is still on, clunking is getting worse, I hear a click noise coming near the transfer case when turning the car off.. Is it worth doing a fluid change as I've heard this may rectify it?? or could it be the actuator gear faulty again after 6months of being replaced ?? Or is it something else ?? Thoughts ?

If you hear clicking, then likely your actuator gear is toast. I don't guess it would hurt to change the oil if you're going to change the gear. Where did you get the gear that you installed?

[dano1200r]

Have you checked the calipers and rotors?

[ryster]

inspection report has suggested Rear brakes pads and rotors requiring changing. Can this cause the issue ?

[tommymulligan]

My rear wheels clicked on tight right hand turns. Changed transfer case fluid and the problem disappeared. I used the Ravenol equivalent to the BMW OEM fluid.