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  #1  
Old 01-05-2016, 09:02 PM
zvizdic zvizdic is offline
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ATC 450 (transfer case) Rebuild

Hi everybody

I did rebuilding of a transfer case on my f25 .
Searched the web and I could not find any help.
I was able to find clutch plates from an atc 350 they are the same as a 450,it requires 7 clutch plates.

Special tools required :
Gear puller
Snap ring external pliers

1 L of BMW ATC oil

Grate Stuff (silicone gasket maker)








Drain the oil from ATC .
Once you pull out ATC the next step is to pull out snap ring on the side that is linking to rear differential then use gear puller to remove flange.






Here you can see the flange is off and the drain plug removed. behind the plug is a magnet that is collecting steal shavings you kneed to clean .





This picture shows with yellow lines up on assembly to line up a tab(arm) of ball cam assembly with its seating.







Prying apart the lid using a screw driver (2 spots). some resistance to be expected because its coming off a bearing and 2 dowel pins and silicone gasket material.








Closer lock at clutch assembly

I used a couple of pieces of wood to apply some pressure to the plate beneath the snap ring and my friend removed the snap ring.







In this pic you can see the snap ring and a washer. I would imagine by adding a tin washer beneath the thicker one, something like 0.025" could be a quick hack or temporary fix.






Showing 3 ball clutch pressing mechanism







Make wire hook to pull plates out. basically remove all plates and replace whit new ones in same order.









In my case bearings and chain are in a ok shape all that is left is to reassemble,
in reverse order.




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  #2  
Old 01-06-2016, 02:34 AM
jgroarke jgroarke is offline
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  #3  
Old 01-06-2016, 08:13 AM
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Awesome!

I want to do a fluid change in mine, but haven't had time to get under the car, remove the shields and look... is there definitely a drain plug and a separate fill plug? I'm planning on buying new plugs and BMW fluid and doing this ASAP. I did it on my last X3 and it was very easy. I just want to confirm that there are two plugs.
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  #4  
Old 01-06-2016, 09:33 AM
zvizdic zvizdic is offline
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Hi jman

Just lock at a picture #4 you can see 2 plugs
Drain plug is removed and the other one is on behind the bearing cover.
You going to need oil pump to fill the ATC
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  #5  
Old 01-06-2016, 10:22 AM
poker838 poker838 is offline
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How many kms on your X3? Just curious at what point would require this service - my dad's 2011 is at 65000 kms.

thanks!
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  #6  
Old 01-06-2016, 11:18 AM
zvizdic zvizdic is offline
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Hi poker

77000 km.
Poor maintenance from previous owner I guess.

Tire were uneven worn out that's way Atc suffered excessive wear.
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  #7  
Old 01-10-2016, 04:38 PM
zvizdic zvizdic is offline
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Hi again

I got my enet cable and e-sys
Connected to my f25 as per suggestion of youtube video saved FA and SVT files .
Ecu associated with controlling transfer case actuator is LMV_FR
Can anybody help me with coding the actuator that is from F10 vehicle.

Last edited by zvizdic; 01-12-2016 at 04:22 PM. Reason: wrong ecu name
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  #8  
Old 03-05-2016, 09:49 PM
zvizdic zvizdic is offline
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Update atc450 final fix

I changed the clutch and the problem was still there. So after studying my pictures for a couple of days I noticed that the cam plate wore out the aluminum housing seat. Eureka!

When you look at my picture, I've got a red arrow designating the truss that the worm gear applies to the cam gear and you can see that the protruding portions of the cam plate have an empty portion right at the rib support of the housing. So the reason why the cam plate is wearing out the housing is because the cam plate does not have full circular support on the housing so it wears out the housing and kicks out the cam set out of centre.
To fix this flaw in design I decided to fill the space with a shim of 2mm/.08" more or less depending on your case.
The shim as you can see is lightly tack welded and fitted for ease assembly.
In my case one of the fingers that is locketing cam plate brock so I fix that by drilling and taping for M6 screw (see picture )

The conclusion is Magna actimax transfer case has design flaw (maybe intentional )

In the process of fixing I update car to a newest software level (learned IstaD -P and Esys programing).
Tray 2 used actuators which wore reprogrammed numerous times including some of european car specialist .

I decided to find a fix to this problem so to pay back to this community of people sharing that I learned many things from (thought of giving up couple times ).








Last edited by zvizdic; 03-06-2016 at 08:52 AM.
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  #9  
Old 03-10-2016, 07:51 AM
Gasman123 Gasman123 is offline
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Transfer case

Thanks for the info I have a2012 x5 and was told transfer case is bad 67 ,000 on the clock
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  #10  
Old 03-10-2016, 07:58 AM
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Doug Huffman Doug Huffman is online now
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Quote:
Originally Posted by Gasman123 View Post
Thanks for the info I have a2012 x5 and was told transfer case is bad 67 ,000 on the clock
Well they are talking about BMW transfer cases, but your car and transfer case is at least slightly different. Yours is an E70 and an ATC-700.
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Old 03-10-2016, 01:55 PM
Gasman123 Gasman123 is offline
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Transfer case

Quote:
Originally Posted by Doug Huffman View Post
Well they are talking about BMW transfer cases, but your car and transfer case is at least slightly different. Yours is an E70 and an ATC-700.
I have the atc 450 also it's in the shop now. I'm looking for some help from bmw or I will be doing this myself it would be nice if there where some parts out there to rebuild this unit from looking at what you did the problem may be in the case
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  #12  
Old 03-10-2016, 05:49 PM
zvizdic zvizdic is offline
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Quote:
Originally Posted by Gasman123 View Post
I have the atc 450 also it's in the shop now. I'm looking for some help from bmw or I will be doing this myself it would be nice if there where some parts out there to rebuild this unit from looking at what you did the problem may be in the case
It is really easy you just have to weld that shim and make it slip fit for easy assembly. That is if it's worn out like my witch is probably the case.

Btw I Called Bmw no more exchange option you have to buy new transfer case which is CAD$5640 before tax .
Don't expect help from BMW that is where they making best money on parts and labor .
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  #13  
Old 03-28-2016, 01:58 PM
Gasman123 Gasman123 is offline
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Just removed my transfer case and there is wear in the same spots as yours but not as bad, there is a flaw in the case that the only part showing wear as soon as I learn how to post pictures I will
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  #14  
Old 03-28-2016, 02:48 PM
zvizdic zvizdic is offline
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Trust me little wear is enough to make the case slip worm gear of cam gear. I did not make big deal off it at first. It took 3 times to take the case apart and study workings off components to figure out. I didn't even need to replace cluch plates it would still be ok.
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  #15  
Old 03-28-2016, 04:11 PM
Gasman123 Gasman123 is offline
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Quote:
Originally Posted by zvizdic View Post
Trust me little wear is enough to make the case slip worm gear of cam gear. I did not make big deal off it at first. It took 3 times to take the case apart and study workings off components to figure out. I didn't even need to replace cluch plates it would still be ok.
I can see that I would hate to buy another case for this to happen again, I have a module on the front of mine I had to move it to get to one of the case bolts any thought as what this is?
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  #16  
Old 03-28-2016, 04:30 PM
zvizdic zvizdic is offline
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If you asking what that module is .
That module is a controlling unit with servo motor built in and it's driving cam gear witch is engaging and disengaging cluch and transfering power to front wheels .
You can take that off the case .
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  #17  
Old 03-29-2016, 11:34 AM
Gasman123 Gasman123 is offline
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Quote:
Originally Posted by zvizdic View Post
If you asking what that module is .
That module is a controlling unit with servo motor built in and it's driving cam gear witch is engaging and disengaging cluch and transfering power to front wheels .
You can take that off the case .
Can't get snap ring on flang is there a tool you used I see there is a o ring washer then snap ring is this right
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  #18  
Old 03-29-2016, 03:28 PM
zvizdic zvizdic is offline
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If you got any mechanical skills it's easy to take apart.
To take flange off you need external snap ring tool and gear puler .
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  #19  
Old 03-29-2016, 06:14 PM
Gasman123 Gasman123 is offline
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Quote:
Originally Posted by zvizdic View Post
If you got any mechanical skills it's easy to take apart.
To take flange off you need external snap ring tool and gear puler .
I had a little trouble getting the snap ring back on not off anyway I just finished runs great a big thanks to you
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  #20  
Old 03-29-2016, 07:04 PM
zvizdic zvizdic is offline
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Glad to give back to community.
Hopefully BMW will correct this in future.
Did you learned to post pics it would be helpful to other people trying to do the same.

Last edited by zvizdic; 03-29-2016 at 07:11 PM.
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  #21  
Old 04-04-2016, 11:36 AM
Snowdrift Snowdrift is offline
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Hi Zvizdic,

I have a problem with an BMW X5 with ATC 450, the car streching when turn steering, seems that 4x4 are still on, when turn, when straight all is correct. No warning lights. What did you notice driving your car or you have warning light on?

Many thanks
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  #22  
Old 04-04-2016, 02:24 PM
zvizdic zvizdic is offline
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Ok I guess I should explain symptoms for a transfer case about to go bad.
First I notice is same as you experienced no 4x4 light on straight drive it's coming on with turn to left or right and it stays on until restart. I try to clear Error but it crept coming on over and over. Bmw software points to transfer case actuator so I replaced couple of them no lack.
Your only choice is to take transfer case of and rebuild as explained in tutorial or buy new one.
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  #23  
Old 04-04-2016, 02:52 PM
w5xz w5xz is offline
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Nice job and write-up! I can't help but wonder 'lifetime oil fill' ??

I think i'll try changing the oil every year or two; first drain was pretty black..2011 x328i, 25k miles.

The BMW transfer case synthetic oil sure does not LOOK like 75w90...much much thinner than that, IMHO.

regards, Dan
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  #24  
Old 04-04-2016, 04:01 PM
zvizdic zvizdic is offline
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My was black to and since I disassembled transfer case 3 times change oil only the first time.
But on second time of disassemble it was looking pretty blackish but I was not going to change again since it was $50 /L.
Definitely need change at 50k or 75k km
Lifetime oil is crazy only fools would feel for that one.
Same as 24000 km for engine
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  #25  
Old 04-05-2016, 02:26 AM
Snowdrift Snowdrift is offline
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Quote:
Originally Posted by zvizdic View Post
Ok I guess I should explain symptoms for a transfer case about to go bad.
First I notice is same as you experienced no 4x4 light on straight drive it's coming on with turn to left or right and it stays on until restart. I try to clear Error but it crept coming on over and over. Bmw software points to transfer case actuator so I replaced couple of them no lack.
Your only choice is to take transfer case of and rebuild as explained in tutorial or buy new one.
Dear,

Many thanks,

In my, never pop up 4x4 light, only scratching when turn, no errors when diagnostic? Had you the lights on? Do you think i have the same problem as you?
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