Transfer case actuator gear

[vinyldude]

I just finished the gear repair for the second time. The first time was around 120,000 miles late 2016. Now the miles stand at around 180,000 four years later. Too bad these gears marketed to be better than the original do not seem to last forever either.


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[91e34M5]

I pretty much had the same issue. After consultation with an BMW specialist, he advised that I need to reset the limits of the actuator motor after gear replacement. ON the last gear replacement, I used my Foxwell NT510 to go into the TC module and let it reset the limits. I don't know yet how long before I have to replace the gear again, but I've traveled around 30,000 miles since.

[dukedkt442]

How often do you change the transfer case fluid? I can't say that it's the cause, but I change my transfer case fluid every 20k miles and am at 172k miles on the original gear, never had a single X-drive issue.

[vinyldude]

How often do you change the transfer case fluid?

I changed the fluid when the gear was replaced the first time at 120k. The main reason was that the "too worn fluid" code was one of the VTG error codes. I did the clutch calibration procedure with DIS as well back then.
The same error code hasn't re-appeared yet so I haven't jumped to change the fluid again. However, I suppose 60k miles might be a reasonable interval to voluntarily do the fluid service again.

Is your thinking that the clutch mechanics will get stiffer for the actuator gear to turn when the fluid gets older?

[dukedkt442]

I changed the fluid when the gear was replaced the first time at 120k. The main reason was that the "too worn fluid" code was one of the VTG error codes. I did the clutch calibration procedure with DIS as well back then.
The same error code hasn't re-appeared yet so I haven't jumped to change the fluid again. However, I suppose 60k miles might be a reasonable interval to voluntarily do the fluid service again.

Is your thinking that the clutch mechanics will get stiffer for the actuator gear to turn when the fluid gets older?

Perhaps. That, or the change in fluid viscosity as the fluid wears forces the actuator to work more.

I've also never ran through a clutch calibration procedure, nor reset the worn fluid code. The clutches self-calibrate on every start-up.

[dukedkt442]

Another thought is as the fluid ages, its ability to absorb heat and conduct it to the case diminishes, so more heat is transferred to the plastic actuator gear.

[1st Roundel]

I pretty much had the same issue. After consultation with an BMW specialist, he advised that I need to reset the limits of the actuator motor after gear replacement. ON the last gear replacement, I used my Foxwell NT510 to go into the TC module and let it reset the limits. I don't know yet how long before I have to replace the gear again, but I've traveled around 30,000 miles since.

I don't recall seeing this function in my Foxwell when I replaced the gear. Is it simply in the pull down ECU menu?
thx

[Natezo]

What’s the procedure to reset the limits with the foxwell? I have one but didn’t know it could do this. Thanks!