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The E46 XI was produced from 01-05 in sedan and touring body styles. Powered by either a 2.5L inline 6 in the 325xi or a 3.0L inline 6 330xi. Discuss all thing about BMW AWD E46 'Xi' here.

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Old 10-10-2010, 08:38 PM   #1
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Join Date: Jul 2007
Location: Canada
Posts: 157
My Ride: 2004-325xi,87-5000TQ
Unhappy Xi Transfer case - anyone else seen this ???


So I was checking things out under my car, and I happened to notice this crack! I don't recall hearing any cracking or thumping when shifting gears, but I did on occasion hear something backing down the driveway in the morning when I went down the dip onto the road, but I doubt this is at all related. The pictures show the crack viewed from the front of the car looking back on the casing. You can also see that where it's split, there's a piece that's shot out and is missing now. There is no other damage around the crack and the rubber mount part that protrudes out past the housing where the piece of metal is missing - the rubber mount protrudes slightly, has no signs of damage, and also my plastic undercover is in one piece... The car still has the CDV in it and I'm not a fan of dropping the clutch, so I'm really at a loss how this has happened .

It's somewhat concerning, if it gets worse and lets lose and/or twists out the whole assembly. The car is a bone stock 325xi with 140 km in Canada.
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Last edited by jc179; 10-11-2010 at 08:24 AM. Reason: typo
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