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Thread: How prevalent are 328d transfer case issues?

  1. #1
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    How prevalent are 328d transfer case issues?

    Hi All,

    Currently have a E46 330xi but looking to get into a 2014 328d for my long highway commute.

    I was excited about the 328d until I started reading that the transfer case issues(mainly failing without warning at low mileage).

    I commute roughly 40,000mi/year...need this thing to last! Is this a common issue to all 328d's? Or a specific range? Are there upgraded parts available?

    Cheers,
    T

  2. #2
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    Where have you seen failures? Curious.
    -Abel

    - E36 328is ~210-220whp: Lots of Mods.
    - 2000 Z3: Many Mods.
    - 2003 VW Jetta TDI Manual 47-50mpg
    - 1999 S52 Estoril M Coupe
    - 2014 328d Wagon, self-tuned, 270hp/430ft-lbs
    - 2019 M2 Competition, self-tuned, 504whp
    - 2016 Mini Cooper S

  3. #3
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    The issues seems to be with the output flange for the rear wheel driveshaft. The material was too soft and would simply grind away due to the low rpm torque on wide geared diesels.
    You can change the flange (probably even on car) before it fails.. flange is around $230.

    OR

    more recently BMW priced the upgraded transfer case at ~$600 for a brand new case. You can't beat that.

    Buy a 328d, haggle for $800 and buy a transfer case with it.
    Mine has over 75,000 miles on it and still original transfer case. Considering buying the upgrade while it's this cheap.
    -Abel

    - E36 328is ~210-220whp: Lots of Mods.
    - 2000 Z3: Many Mods.
    - 2003 VW Jetta TDI Manual 47-50mpg
    - 1999 S52 Estoril M Coupe
    - 2014 328d Wagon, self-tuned, 270hp/430ft-lbs
    - 2019 M2 Competition, self-tuned, 504whp
    - 2016 Mini Cooper S

  4. #4
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    Quote Originally Posted by 328 Power 04 View Post
    Where have you seen failures? Curious.
    There have been a number of posts in f30post (http://f30.bimmerpost.com/forums/forumdisplay.php?f=488) diesel forum, and a few other places.

  5. #5
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    Quote Originally Posted by 328 Power 04 View Post
    The issues seems to be with the output flange for the rear wheel driveshaft. The material was too soft and would simply grind away due to the low rpm torque on wide geared diesels.
    You can change the flange (probably even on car) before it fails.. flange is around $230.

    OR

    more recently BMW priced the upgraded transfer case at ~$600 for a brand new case. You can't beat that.

    Buy a 328d, haggle for $800 and buy a transfer case with it.
    Mine has over 75,000 miles on it and still original transfer case. Considering buying the upgrade while it's this cheap.

    Very interesting thanks for the info...

    Having a reasonably priced upgraded replacement part makes the car interesting again.

  6. #6
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    I find it very interesting that no 440xi/335xi cars, with more torque/hp and presumably the same xfer case, have not reported these problems...
    I think there's something else going on.

  7. #7
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    I'm thinking of getting a TDI now(while they are readily available) and picking up a 328d in a few years when the transfer case issues are a thing of the past...

  8. #8
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    Quote Originally Posted by floydr View Post
    I find it very interesting that no 440xi/335xi cars, with more torque/hp and presumably the same xfer case, have not reported these problems...
    I think there's something else going on.
    Look at the transmission and the differential gear ratios. The high-ish diesel torque at very low rpm is multiplied by the tall gearing, putting big stress on the output flange.
    <edit> looked at the ratios, they're only a little bit taller on the 328d vs 340ix.. The older 335ix seems to have had identical gearing to 328d, but shorter diff gearing.


    I have tuned my 328d to over 330ft-lbs and driven it for over 8000 miles like this, without issues... BUT I still think I will buy a spare transfer case. That price won't last. PN 27108643149




    If I do get the spare transfer case, I will check the flange Rockwell hardness to see the differences between the two.
    There wouldn't be any reason to why you couldn't heat treat / harden the current flange too.
    Last edited by 328 Power 04; 06-22-2018 at 01:01 PM.
    -Abel

    - E36 328is ~210-220whp: Lots of Mods.
    - 2000 Z3: Many Mods.
    - 2003 VW Jetta TDI Manual 47-50mpg
    - 1999 S52 Estoril M Coupe
    - 2014 328d Wagon, self-tuned, 270hp/430ft-lbs
    - 2019 M2 Competition, self-tuned, 504whp
    - 2016 Mini Cooper S

  9. #9
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    Hmm.. here's an additional point.

    I have been driving tuned for the last 8000 miles, but I also disabled the front drive part of the transfer case through some tinkering and coding. (I was contemplating converting the car to full time rwd with front shafts and diff completely removed).

    Doesn't really makes sense if that would be a protective mechanism, because it's the rear wheel output flange that has worn on some people's 328xds.


    I think I will join the above forum sometime.

    Mechanical, diagnostics, and electronics work doesn't scare me. It's kind of fun.
    -Abel

    - E36 328is ~210-220whp: Lots of Mods.
    - 2000 Z3: Many Mods.
    - 2003 VW Jetta TDI Manual 47-50mpg
    - 1999 S52 Estoril M Coupe
    - 2014 328d Wagon, self-tuned, 270hp/430ft-lbs
    - 2019 M2 Competition, self-tuned, 504whp
    - 2016 Mini Cooper S

  10. #10
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    I am sure I am going to regret this post, but I have 60k miles on my wifes 2014xd on the original part.

    I might buy the upgraded part just to have.

  11. #11
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    And as luck would have it I think I need it now ... I never bought it but now I see its $1550 from Tischer. Damnit.

    There is a loud clunking coming from the rear at low speed. You can hear it when going from D to R. I rarely drive this car, but today I drove in a parking garage and it extremely loud, quite noticeable. Driving with the radio/AC off you can hear it when coming to a stop and the car downshifts.

    I will inspect tomorrow ... hopefully its something else.

  12. #12
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    I would inspect before doing any ordering. It may not be that.

    - - - Updated - - -

    If it is that, you can change just the output flange (some $300 instead), but it's no guarantee that it won't wear again. It seems that cars that eat that flange, do it repeatedly. There has to be something going on.
    -Abel

    - E36 328is ~210-220whp: Lots of Mods.
    - 2000 Z3: Many Mods.
    - 2003 VW Jetta TDI Manual 47-50mpg
    - 1999 S52 Estoril M Coupe
    - 2014 328d Wagon, self-tuned, 270hp/430ft-lbs
    - 2019 M2 Competition, self-tuned, 504whp
    - 2016 Mini Cooper S

  13. #13
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    Yep, I will put it on jack stands tomorrow and have my wife go back from D to R while pressing the brakes and I look underneath. Hopefully the car doesn't freak out that the tires are off the ground.

    If it is the output flange, do I need to tear down the whole transfer to change that? Or is it something that I can pop off like the diff flanges?

    Thanks

  14. #14
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    It's held onto the shaft by a C clip. It may need a puller, but should be possible to be changed on car.
    The output flange kit is part number 27107593440
    -Abel

    - E36 328is ~210-220whp: Lots of Mods.
    - 2000 Z3: Many Mods.
    - 2003 VW Jetta TDI Manual 47-50mpg
    - 1999 S52 Estoril M Coupe
    - 2014 328d Wagon, self-tuned, 270hp/430ft-lbs
    - 2019 M2 Competition, self-tuned, 504whp
    - 2016 Mini Cooper S

  15. #15
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    I was able to lift it up today and have a listen. The exhaust on this car is one piece pretty much. To get to the driveshaft I have to dissasemble half the car, way worst than my e46 or e36.

    Check this out and let me know what you guys think.



    Last edited by Slippery; 10-08-2018 at 07:15 PM. Reason: video embed

  16. #16
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    By the way, I was filming while my wife kept cycling the transmission between reverse and drive. She had the foot on the brake pedal all the time.

    When in neutral, all four wheels would start spinning ... I found that odd.

  17. #17
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    Anyone think this is something else before I start tearing down the car?

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