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E46 Xi Forum
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 03-10-2014, 09:02 AM   #1
phildobaggins
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Mechanical help please: Transfer case removal for clutch job

I'm in the middle of my clutch replacement. Can I leave the transfer case on the transmission or does it need to be taken off? The Bentley manual says to take it off but I cannot see why I wouldn't just leave it be.

If anyone in this area has any advice please let me know. Thank you.
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Old 03-10-2014, 09:25 AM   #2
SamDoe1
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You can probably leave it on but read forward a ways in the manual to see if there's anything that will come up that requires the TC removal.

Make sure you swap out the shifter bushings while you're in there.
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Old 03-10-2014, 09:42 AM   #3
phildobaggins
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Definitely, those parts are on my list. I read through the Bentley sections, it looks like the only explanation is that it needs to be removed for easy clearance.
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Old 03-10-2014, 02:50 PM   #4
Tippey764
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There's no reason to not take it off. It's held on by like 5 bolts and isn't that heavy
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Old 03-10-2014, 03:04 PM   #5
phildobaggins
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coolness, i'll take it off tonight and go from there.
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Old 03-11-2014, 12:34 AM   #6
phildobaggins
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I found and removed 4 torx bolts holding the xfer case to the transmission after removing the mounts and transmission brace. Tranny is now resting on my trans jack.

Can anyone confirm if there are 4 or 5 torx bolts holding this on to a 5spd transmission? It looks like it wants to separate but I can only get about 2mm of separation at the bottom. This kinda leads me to belive there is a torx bolt up top somewhere i'm not seeing.

I'm calling it a night but any/all advice is welcome.
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Old 03-11-2014, 02:24 AM   #7
phildobaggins
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this helps, i'll take another crack at it tomorrow.

Last edited by phildobaggins; 03-11-2014 at 02:26 AM.
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Old 03-11-2014, 08:52 AM   #8
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There are 4 bolts from the back of it going into the transmission and one on the front bear the output shaft for the front axle going into the transfer case from the transmission
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Old 03-11-2014, 09:58 AM   #9
phildobaggins
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Excellent, I must be missing 1 bolt on the back/top somewhere. Thanks for your help everyone.
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Old 03-11-2014, 10:41 PM   #10
325xittt
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I had a squirrels nest in hollow space between the transfer case and the Transmission best to take it off and check your seals. Its easier to put shift linkage back together with the tc out IMO. You should consider replacing the shifter linkage bushing and such. Also there some sort of steel guide collar for the shift fork mechanism on the input shaft to the transmission. I wish I had replaced mine as it showed some wear. I had to get the car back on the road so I didn't replace it, So check it out if you are ordering parts
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Old 03-11-2014, 11:22 PM   #11
phildobaggins
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Yeah thanks to everyone the tc is off. I'm down now to just the bell housing. I got my bearings lifting the motor by the oil pan and getting at the trans from a better angle. Tomorrow night I'll take on the bellhousing.
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Old 03-11-2014, 11:23 PM   #12
phildobaggins
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Yeah I'll be hitting all the parts I can while I'm I here. Ever seal and bushing or bearing possible.
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Old 03-16-2014, 01:10 PM   #13
helphos
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Transmission's out- what to do?

Don't forget to install your short shifter! It adds no additional time to the clutch job!
Checkout the threads on how to do it inexpensively!

Good luck!
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