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Thread: The white TC actuator gear has a crack. Can it cause TC calibration issues?

  1. #1
    Join Date
    Apr 2019
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    X3 2008

    The white TC actuator gear has a crack. Can it cause TC calibration issues?

    My transfer case is stuck in "Could not calibrate" state.

    So I am backtracking work that I did (transfer case fluid change and worn black gear replacement where I ran ISTA/D recalibration) and found that the white plastic gear has two small cracks.

    IMG_0212.jpg
    IMG_0210.jpg

    Could this crack be causing the transfer case calibration issue?

    I either plan to epoxy both gears together or put markers on both of them to see if under higher torques teeth are skipping. Under lower torques with servo motor detached from transfer case it appears to be spinning just fine. Any ideas on this plan?

  2. #2
    Join Date
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    2001 525it
    Buy new gear epoxy will not hold it together search on line for the gear

  3. #3
    Join Date
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    Quote Originally Posted by jclausen View Post
    Buy new gear epoxy will not hold it together search on line for the gear
    And is there a precedent that cracked white gear can prevent transfer case from getting calibrated properly? In my case the gear appears to be still rigid. So I was thinking the epoxy could be used to at least verify the hypothesis that it is causing the calibration issue.

  4. #4
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    Yeah,,,[age]...go on and $pring for a new replacement you've earned it friend and then also buy yourself a cold one.

    Sent from my SM-J727T using Tapatalk

  5. #5
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    Quote Originally Posted by X3456 View Post
    Yeah,,,[age]...go on and $pring for a new replacement you've earned it friend and then also buy yourself a cold one.

    Sent from my SM-J727T using Tapatalk

    Here is what I did:
    1. removed the grease that I applied too liberally everywhere on plastic gears.
    2. epoxied together black and white gear to reduce slippage that may be caused by a cracks on white gear
    3. replaced the 12V battery (because the old one had discharged to 4V while car was sitting on jack stands).

    And suddenly TC calibration was successful!!! I believe it was #2 that fixed the issue. Maybe #1 helped to reduce the slippage between white and black gears too. I doubt it was #3, because before I left car disconnected from battery overnight and it did not help to clear any faults.

    P.S.
    Of course epoxy was just a temporary hack to see if it will solve the calibration issue. I don't plan to drive around like that. Now I am getting to get a proper TC actuator rebuild kit.

  6. #6
    Join Date
    Jan 2016
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    2001 525it
    You only need a gear not a kit

  7. #7
    Join Date
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    I too suggest you get a new gear. However, from (personal experience) I know you can simply rotate the existing gear 180 and the actuator will function as new...its true...but you will want that peace of mind a new replaced gear will give. keeping in mind I'm made from a different kind of cloth.

    Sent from my SM-J727T using Tapatalk

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