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E60 / E61 (2004 - 2010)
BMW 5-Series E60 Sedan was first seen in the Unites States in the fall of 2003 with a 2004 Model Year designation. The E61 wagon followed shortly there after. The E60/E61 5 series is now available as a 528i, 528xi, 535i, 535xi, 550i and a 535xi sports wagon! -- View the E60 Wiki

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  #26  
Old 05-08-2019, 08:25 AM
Kurt_ Kurt_ is offline
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The bendy one up top is the vent. The one by the gears is the oil return.
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  #27  
Old 05-18-2019, 06:59 PM
Kurt_ Kurt_ is offline
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I'm probably getting ahead of myself here without pictures, but I've got the car up on stands right now and the new transfer case is installed. I still need to button it up a bit before I go for a test drive.

I cracked open the old case and everything seems to be intact. There's no bits in the fluid, despite its dark colour. The first thing I
notice is how difficult it was to get the case off after breaking the two halves free. The rear bearing for the front driveshaft came out of the case and is stuck to the shaft. It has a bit of play. The others do too. They spin well, still.
The clutch pack has a wider gap compared to the new case, at least the thickness of a clutch plate. No sign of a broken one, it's just a wider gap. The pack as a whole has more slop to it. That is, each friction plate can move about 1-2mm off of the concentric axis. I actually gave up trying to put the outside gear back on... The bell one that fits over the outside edges of the clutch pack. Whatever you'd call it.

The plates aren't staying concentric. My snap ring pliers can't get the clutch pack snap ring off to investigate further, but I'd say something's broke in there. It still seems to function. Just with a lot of play.

Here's hoping the new case fixes my problem. ...I just discovered a broken strut mount, but this must have happened recently so I don't think that's the problem.

Last edited by Kurt_; 05-19-2019 at 05:30 AM.
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  #28  
Old 05-19-2019, 03:09 AM
mcardlepm mcardlepm is offline
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Be afraid... be very afraid

Within a month of buying my 07 with 240k miles, I realized I needed the Bentley book; I've already replaced both DISA valves, and am still chasing a random error/bad throttle body remapping, but had the TC actuator motor failure you've experienced.

On many forums I've seen people happily advise to drive the car with the failure, since "it's just in RWD now." And I've also seen the occasional TC horror story after someone has done just that. Think about it: it's an actuator failure, a component with a motor and gears at that. So it can fail in one of three modes: fully disengaged, fully engaged, or somewhere in between. Fully disengaged, you have RWD. Fully engaged, you have 4WD, all the time, which is why only some people report front-end stiffness and trouble low-speed steering, hard on the tires etc. But the nasty one would be partially engaged: think about what that would do to the TC clutches, hence the occasional "I ended up replacing my transfer case because my clutch paks burned out a week later."

I love how my BMW drives when it's "right" but BMW ownership feels more like co-dependency and denial - no wonder they depreciate so badly. (Do I really need 28 microprocessors, or three intakes-in-one, considering the downside of engine destruction if a disintegrating DISA is ingested?) I've been a serious DIY mechanic for over 40 years, done motor and tranny swaps, complete engine rebuilds in cars, trucks and air- and water cooled bikes. (So in that sense I'm not a wrench noob.) I've had my 07 530xi for about four months now, and getting it as cheap as I did I anticipated problems, immaculate though it was in and out. (Doctor owned.)
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  #29  
Old 05-19-2019, 01:24 PM
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Burning2nd Burning2nd is offline
Under the lift arms
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IME bmw makes rear wheel drive cars. and the service history, and story's and parts cost reflect that

all of there x drives handle like a tank.. Imo

bmws earily ix's in the late 80's were bullet proof

the first 4wd sold to the public the e30 325ix

*not counting the 1930's
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Last edited by Burning2nd; 05-19-2019 at 01:26 PM.
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  #30  
Old 05-20-2019, 02:03 PM
Kurt_ Kurt_ is offline
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You say that like driving a tank is a bad thing. I think when it's working the all wheel drive system is pretty good and improves the car's driveability even in dry conditions.

I think my next car will be an audi, though. After seeing how reliant this system is on electronics it makes me want a simple, all mechanical awd system.

Finger's crossed the new case fixes my issue. I'm not sure how to go about selling the old transfer case... It seems to be functional but it seems like replacing it fixed my problem. That's a $600 case on ebay working.

Last edited by Kurt_; 05-20-2019 at 02:09 PM.
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  #31  
Old 05-22-2019, 05:58 AM
Kurt_ Kurt_ is offline
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So, I gave it a few days. Error is still happening, but less frequently. Transfer case is no longer throwing codes, which is nice.

I'm confident the transfer case and module are working fine. Maybe a loose connection?

DSC is throwing two errors:

6E83 - appears to be tpms related. I want to disable the whole system and revert to FTM. I don't think this is causing a transfer case issue.

5DEC - what's this code? I'm getting conflicting answers. Transfer case malfunction or rear left speed sensor. Bmwfault.codes shows 5DEC to be "DSC: Transfer case malfunction". But, for an older dsc it is described as " wheel rpm sensor rear left - short circuit to positive ". Having just completely replaced the transfer case I'm not inclined to believe it is malfunctioning, but maybe it's getting a bad input.

Wheel speed sensors appear to be functioning properly, all within 1km/h of each other. But on that test run, I didn't get any errors. It could be intermittent. I'll have to inspect them all.

I'm running out of things to troubleshoot... Any idea which sensors the transfer case uses for input?

Edit: I drove a bit today, and... no more error? We'll see. It's sporadic and pops up every now and then during seemingly random conditions. But at least mostly working now. It has happened a few times driving up hills now.
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Last edited by Kurt_; 05-24-2019 at 05:02 AM.
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  #32  
Old 05-23-2019, 06:36 PM
Kurt_ Kurt_ is offline
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So now I'm digging into the DSC sensors. I found this document that describes all of them and their function: https://www.newtis.info/tisv2/a/en/e...switch/XenQpEU
It appears there is a DSC sensor module underneath the driver's seat. This module does yaw rate and longitudinal acceleration. My yaw rate and lateral acceleration won't zero on the right. The sensor uses two piezoelectric spring contraptions to sense acceleration. If one's buggered that might be feeding garbage to the DSC.

Since my wheel speed sensors look fine on the computer, and I'll be double checking the connections when I install coilovers this weekend, I'm tempted to replace this module and see if I can zero it. They're $25 used.

There's also this tidbit:
Quote:
The following advantages result from active wheel-speed sensors:
rapid and reliable detection of the direction of travel
improved activation of the gearbox control
Improved actuation of navigation system
So I don't want to rule out an intermittent wheel speed sensor just yet. Perhaps a cracked disc.
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Last edited by Kurt_; 05-24-2019 at 04:16 AM.
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  #33  
Old 05-24-2019, 05:18 AM
mcardlepm mcardlepm is offline
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Ideas

You may have considered this, but the module you describe could easily be damaged by water, say, from a blocked AC or moonroof drain, if water ever accumulated in the passenger footwell. (The trunk TPM module is similarly easily damaged by water in the trunk.)

Also (and you may have ruled this out) a bad crankshaft position sensor, of all things, can trigger random transfer case warnings with a signal dropout, but with the Foxwell reader you'd see a CPS error message.
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  #34  
Old 05-24-2019, 06:10 AM
Kurt_ Kurt_ is offline
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I'll keep that in mind if the DSC sensor doesn't fix it. I was cheap and lazy so it's coming from lithuania at regular speed shipping.

This car spent most of its life in quebec, and cold seems to be the real killer here.

Back in post 4, I got an error about DSC "no specified nominal torque".

Then, from the DSC functional description,
Quote:
All-wheel control
The dynamic stability control (DSC) specifies the target value for 4-wheel drive control with xDrive. The DSC control unit calculates the locking moment for the multi-plate clutch in the transfer box. The nominal value depends on the tendency of the vehicle to oversteer or understeer and the wheel slip. The target value is sent on the PT-CAN to the VTG control unit.
So, if the DSC sensor is glitching, it may occasionally not have a nominal torque to send to the transfer case control unit, which would cause an error. It might even, say, suddenly and completely disengage the clutch on a 0 Nm signal.

If that's it, I have an extra, working transfer case. I won't get my time back but I'll net a profit on this repair!

Last edited by Kurt_; 05-24-2019 at 08:54 AM.
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