2006 X3 - Replaced transfer case gear, still 3 lights and "actuation error"

[Corellian Corve]

Before spending money on rebuilt transfer case. Bought my parents a nice 2006 X3 with the trifecta lights. Assumed it was a bad gear in the actuator motor since the car was otherwise in fine shape.

Pulled the motor today and the gear was actually fine. Replaced it anyway.

I wanted to test the motor, so I hooked up my Launch and went to the Actuation Tests to try and spin the motor. I connected the electrical connections but didn't put the motor back on the vehicle - left it hanging. Did the test, and the gear spun for a second then the Launch said "actuation failure" and it wouldn't spin it again.

I thought the problem might be that the motor needs to be connected to the transfer case itself. I reconnected the motor, and ran the tests again "actuation failure"

The Launch also had a "recalibrate transfer case motor" procedure (start the car, idle, and in Park) and I tried the calibration test - once again "actuation failure"

So now I'm stumped. The motor spun for a very short time. After that, every other test I got the same failure error.

So my question is - is there a good process to determine if the problem really is the transfer case? Or if perhaps the motor itself failed.

Thoughts?

[jclausen]

Have a shop diagnose it

[Corellian Corve]

I don't want to have to pay a shop diagnose it. I have INPA, NCS Expert and other tools as well as a lift. I'm looking for people experience on how to diagnose it myself so I can learn.

[vinyldude]

It has been a long time since I dealt with mine, and because of that this may not be 100% accurate.
However, in addition to the actual motor the motor assembly has also some sensors (of sorts) that monitor how the gear rotates. I seem to remember opening up that whole unit and cleaning up both the mechanics and the sensors inside and checking that all the electrical contacts were fine.
It is not super hard to do, and who knows might help in your case also.