BMW / DIY

How to Change the Transfer Case Fluid in a 2022 BMW X5 xDrive40i

• by Oleg

A BMW X5 transfer case fluid change requires a fluid extractor and diagnostic equipment. Access may also require removing the transmission crossmember. This guide is based on a service plan for a 2022 X5 xDrive40i (G05); confirm your vehicle’s equipment and current BMW repair instructions before starting.

Safety: support the transmission before removing the crossmember. Raise and support the vehicle at the approved points, then support and secure the transmission using the equipment and method in the applicable BMW instructions. Maintain that support until the crossmember is securely reinstalled. Never work under a vehicle supported only by a jack.

Parts and supplies

  • BMW DTF-1 transfer-case fluid: Have one 1-liter bottle available. BMW’s bulletin discusses approximately 0.7 liter; fill according to the applicable procedure, not by emptying the bottle.
  • New filler plug with O-ring: BMW reference 33117525064; confirm fitment for your vehicle.
  • Gloves, eye protection, clean wipes, and a container for used fluid.
  • Replacement crossmember and other access fasteners as specified by the applicable VIN-specific instructions. The original plan’s candidate hardware and renewal requirements remain unconfirmed.

Tools

Check the actual fasteners and clearance before starting. Socket sizes below are preparation leads, not a verified list for every X5.

  • 14 mm internal-hex bit socket, preferably low-profile — candidate for the filler plug.
  • E10 external Torx socket, plus an E-Torx set — check the installed fasteners.
  • 13 mm, 16 mm and 18 mm sockets, ratchet and extensions — candidate sizes for access hardware.
  • Torque wrenches appropriate for the applicable fastener values, including 60 Nm.
  • Fluid extractor with suitable narrow pickup, clean refill pump and measuring container. BMW specifies tools 0 493 337 (00 2 080) and 2 457 963 for extraction.
  • Rated vehicle lifting and support equipment, and the specified transmission support and securing strap.
  • BMW ISTA or a compatible diagnostic system with both the transfer-case oil-change and calibration functions.

The socket suggestions come from a G05 video and a general transfer-case guide. The G05 video does not show proper support of the assembly during crossmember removal; follow the safety instruction above instead.

Before you begin

Obtain the current BMW transfer-case oil-change and crossmember instructions for your VIN, including the fastener replacement rules, torque, angle and sequence. Confirm access to the diagnostic functions and suitable fluid-handling tools before disassembly.

The original plan identified three short bolts, three long bolts and one mount bolt as candidates. Their exact fitment and renewal requirements were not established. Do not assume reuse is permitted or that the whole set must be replaced.

Prepare and support

  1. Raise and support the vehicle safely at the approved lifting points. Connect the diagnostic system.
  2. Remove the necessary underbody panels. Before removing the crossmember, support and secure the transmission as specified by BMW. Follow the applicable removal instructions and track the fasteners.
  3. In the diagnostic system, select Service functions → Drive → Transfer box VTG → Oil change. Follow its prompts throughout the service.

BMW X5 transfer case fluid change: extract and refill

  1. Open the filler plug and extract the used fluid with the appropriate equipment. Collect the fluid for proper disposal.
  2. Add approved DTF-1 fluid using clean equipment. Follow the diagnostic prompts and BMW’s applicable filler-level instruction; do not pour in the entire one-liter bottle by default.
  3. Install a new applicable filler plug. BMW’s SIB 27 02 20 specifies 60 Nm (44 lb-ft) for the M22 plug. Confirm that this applies to the installed plug and current instruction.

Reassemble and calibrate

  1. Reinstall the crossmember and underbody panels using the applicable BMW fastener replacement, sequence and torque instructions. Keep the transmission supported until the crossmember is securely installed.
  2. Run Service functions → Drive → Transfer box VTG → Calibration and follow the diagnostic prompts.
  3. Check for leaks and confirm that supports and panels are installed and both diagnostic functions completed. Record the date, mileage, fluid and amount used, fasteners replaced, and any follow-up.

Torque reference

  • Transfer-case M22 filler plug: 60 Nm (44 lb-ft) per BMW SIB 27 02 20; confirm applicability.
  • Crossmember-to-mount and crossmember-to-body fasteners: Verify torque, replacement rules, angle and sequence in the current VIN-specific BMW instruction 22 32 050.
  • Underbody panels and other disturbed fasteners: Identify the installed hardware and use the applicable VIN-specific instructions.

BMW’s bulletin addresses a shudder diagnosis; it does not establish a routine service interval or mean this vehicle has that fault. For current repair instructions, consult the BMW technical information portal.

Video references

Warning about the second video: It does not show the transmission and transfer-case assembly properly supported before crossmember removal. Do not follow that part. Use the support equipment and method in the applicable BMW instruction, and keep the assembly supported until the crossmember is securely reinstalled.

The video descriptions were checked, but the videos were not reviewed frame by frame. Use them alongside the current BMW repair instructions.

Explore more BMW DIY articles for other maintenance and repair topics.

DIY

How not to change flat tire

• by Oleg

A cutaway view of a car final drive unit which contains the differential
A cutaway view of a car final drive unit which contains the differential

I watched the funny scene the other day. My neighbor minivan fell off the jack. It fell hard on its belly when the guy removed the flat tire. It could ended up very bad if somebody got hurt. Luckily just van’s belly had  couple of scratches and that was it.

So guess why it fell off the jack?

You guessed it right – the human error. Or I’d call it stupidity in this case. The owner of the minivan did not engage the parking break nor he ensured by any other means that the car would not roll.

The guy was changing one of the front tires of  front wheel drive Toyota Sienna. Once the flat tire was off the ground, lugs were  removed and he shook the tire the minivan rolled back a little bit, just enough to fell off the jack.

The lesson there for owner was that the differential lets one wheel roll freely once another wheel is off the ground even if transmission is in “P” (Park).

[image credit: wikipedia]

DIY

E39 Manual Transmission Fluid Change

• by Oleg

After a brief struggle with my parsimony, I have finally decided to buy original BMW transmission fluid. Sticker on side of gearbox was worn out, but it was of yellow color indicating that I needed MTF-LT-2 fluid. Local BMW dealer had it for MSRP price about $140 for 5 liters. It is a bit more expensive compared to everybody’s’ favorite Red Line MTL, which one could buy from for example OGRacing for just under $9 per liter.

The manual gearbox fluid change is really easy DIY project.

You will need the following tools:

  • 17 mm 6pt socket
  • Some ratchet
  • 17 mm box end or combination wrench, 6pt is the best in my opinion since plugs made from some very soft metal and you can very easily strip plug’s flange if using open ended wrench.
  • Torque wrench
  • Some hand pump
  • one or two feet of clear plastic tubing
  • Floor jack or similar to jack up the car

First of all you’ll need to jack the car up. I usually just drive rear wheels onto ramps and jack up front of car with floor jack, then secure jack stands. Some people drive front wheel onto ramps and jack up the rear. I personally find it a bit dangerous since car can roll away once rear wheel s are off the ground and besides my E39 has rubber jacking point in the front and nothing except rear differential on the back that I could use as jacking point.

Find transmission under the car after car is off the ground and leveled. Read the label and make sure you are going to use the right fluid for you gearbox. Here is view of transmission from under the car.

Photo from BMW325i.NET

Before you remove drain plug make sure that fill plug is not seized. And definitely use either sockets or box-end wrenches to break seize. I almost stripped my fill plug flange when tried to use open end of wrench. Believe me it is very soft.

Here is what color fluid came from my gearbox after 52000 miles. I seriously doubt that it is healthy to have it in the gearbox for the life of car. Well I have to agree with thought that the lifetime fluid is most likely BMW marketing gimmick to attract more customers. It is very unlikely that BMW cares what happens to our cars after 50000 mile warranty and they will gladly offer us replacement transmissions for one forth of car price.

Once plugs are removed and old fluid drained. Replace drain plugs and torque it, on my BMW E39 car it is to 70 Nm. Using hand pump and plastic tube pump transmission fluid into fill hole until it overfills and it starts to leak out of the fill hole. Replace fill plug, tighten it to same torque as drain plug (70 Nm). Check for leaks and you are done.

One more thing, do not forget to lower your car on the ground.

DIY

Are there any tricks for using cheap spring compressor on E46 BMW?

• by Oleg

Is there any trick/technique/know-how regarding how to compress front strut spring with cheapo spring compressors like these ones, maybe location when you bite on the spring matter? I have all three of them know, borrowed and even bought last one. But I could not release the spring so it rests on lower rubber pad nicely.

strut spring compressor 1Strut spring compressor 2Strut spring compressor 3

My latest attempt last night looked almost as it should be. Just on one side rubber pad seamed a little bit off. And here is how it looked by this morning. Spring pushed rubber out completely on one side. So I have to compress spring again and try to realign everything. I just wonder what I was doing wrong since I can not get spring in place correctly.

I also wonder if compressors like the one below works on E46 since although they look similar BMW’s one shown in TIS. The one from TIS uses kind of ring adapter to press against upper plate. For some reason it seams like it should compress spring more evenly. Did anybody try such compressors?
BMW Spring Compressor fro TISHere is screenshot from TIS. The tool is shown assembled for E46 and upper adapter (it is the right one on the picture) is actually a ring. It does not look like anything from kit above could be used like that ring. And without such ring it would be worthless as any other cheap compressor just because there are not enough coils in spring