Brake, ABS, and 4X4 lights all lit. Clicking / juddering sound from transfer case “4X4 inactive” message.
Attached to the transfer case is an actuator motor, within in this there is a poor quality Nylon plastic gear, this is turned by a metal worm gear. Over time the Nylon wears down and strips and leads to the gear not turning; this results in the symptoms noted above. BMW do not supply this part as a spare, they will provide at vast cost a complete replacement motor, this however will fail again because of the Nylon gear.
Replace just the failing component the Nylon gear with our replacement gear made from a plastic / Carbon Fiber mixture; a far better quality part than OEM. This will repair the issue and save the cost of a new actuator motor that would just fail again.
2.0d 2003- 2006
X3 E83 LCI
3.0i 2003 (Oct onwards) -2006
4.8is 2003 (Nov onwards) -2006
BMW X5 E70
X5 M 2008-2013
BMW X5 E70 LCI
BMW X6 E71
40dX some models
X6 M 2008-2014
X6 Hybrid 2009-201
Associated part numbers:
ATC 400 ATC 500 ATC 700
27107566296GR, 7-10-7-566-296GR, 27 10 7 566 296GR, 27107566296GR, 27-10-7-566-296, 27 10 7 566 296 , 27107566296, BOSCH 013000850, 8473227771, 8472227771, 09-3509-010, 9 3509 010, 093509010, 2710 7528559-01.
Teachers! Did you use this instructable in your classroom?
Add a Teacher Note to share how you incorporated it into your lesson.
Step 1: Note Orientation of Components
Take note of the position of all parts of the actuator, refer back to image for reinstallation.
Note resistor on back of actuator, take care not to damage when carrying out repair, (removal is recommended for repair)
Step 2: Remove Motor
Unscrew 4x bolts and remove motor body.
Remove plastic module noting orientation and remember to locate seals on either side of module for reinstall.
Step 3: Remove C Clip
Remove retaining C clip, this can be done with a combination of screw drivers. The easiest method we have found is to use circlip pliers to open the C then inserting a small flat head screwdriver in the space created at the top of the C to allow removal.
Step 4: Remove Cover
Lift off cover. Work around edge with sharp flat head screw driver, ease away at edge and increment size of screw driver to release cover.
Step 5: Clean All Components
Clean up module and motor points with compressed air or suitable cleaner.
Remove gear and clean all components of actuator housing.
Step 6: Fit New Gear
Grease up new gear and replace worn gear.
Grease worm gear and gear shaft.
Follow guide in reverse for reinstall, take note of orientation of all parts and all seals and washer.