E46 BMW Social Directory E46 FAQ 3-Series Discussion Forums BMW Photo Gallery BMW 3-Series Technical Information E46 Fanatics - The Ultimate BMW Resource BMW Vendors General E46 Forum The Tire Rack's Tire Wheel Forum Forced Induction Forum The Off-Topic The E46 BMW Showroom For Sale, For Trade or Wanting to Buy

Welcome to the E46Fanatics forums. E46Fanatics is the premiere website for BMW 3 series owners around the world with interactive forums, a geographical enthusiast directory, photo galleries, and technical information for BMW enthusiasts.

You are currently viewing our boards as a guest which gives you limited access to view most discussions and access our other features. By joining our free community you will have access to post topics, communicate privately with other members (PM), respond to polls, upload content and access many other special features. Registration is fast, simple and absolutely free so please, join our community today!

If you have any problems with the registration process or your account login, please contact contact us.

Go Back   E46Fanatics > E46 BMW > E46 Xi Forum

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.

Reply
 
Thread Tools Search this Thread Rating: Thread Rating: 1 votes, 5.00 average. Display Modes
Old 02-20-2013, 07:14 PM   #1
Cloudbase
Registered User
 
Join Date: Apr 2009
Location: Superior, CO
Posts: 65
My Ride: M Coupe, 325xiT
Holy Pain in the A$$ - Replacing XI Transfer Case Bushing (Homemade Tool Content)

Hey everyone. I got back into an E46 XI wagon last summer and it has become out road trip machine / gear hauler. 2003 (10/02 build) XI, Cold Wx Package, GM Auto (first auto BMW ever ), presently 95,000 miles. We've taken 3 road trips to very remote areas and suffered 2 catastrophic breakdowns.

I love the car.



At 90K miles I completely overhauled the entire cooling system, belts, tensioners, spark plugs, oil change, diff's & transfer case oil, brake fluid, Dice Simplicity, for a road trip over New Years. Coming home the fuel pump failed at the top of Trout Creek Pass in Southern Colorado. Coasted 9 miles back into town and got a $$$$$$$ 130 mile tow home.

At the end of January we rallied to UT for a snowboarding trip. On the way home, in one of the most remote parts of Utah between Price and Green River the pax side motor mount failed. It put the fan into the radiator (that I had literally just preventatively replaced). I was passing a truck at redline and heard an ominous sound, but didn't know what happened till the low coolant light came on about 10 miles later. I was able to limp it in to a gas station in Green River (coasting the last mile because the temp started climbing).





I JB welded the radiator enough to get it the remaining 250 miles home.



The motor mounts weren't too hard to replace once I dropped the front subframe. New and old pax side motor mount.



I figured I better do the tranny mounts too while I was in there. Here is where the real drama began. The XI has a single giant pressed-in bushing in the transfer case similar to a subframe bushing. The automatic gearbox drain pan gives about 2" of space on the front side of the mount. The exhaust gives about the same on the back. My exhaust studs are corrosion welded together at the down pipe and front of the exhaust. There wass not way for me to break it, even with copious amounts of heat. Cutting and replacing the studs with bolts without pulling headers in my garage was not an option. I was left with having to somehow pushing the bushing out in the confines of the space between the exhaust and the gearbox.

XI Transfer Case Bushing (instead of traditional tranny mounts).





Heat wasn't an option because once the bushing started burning it would burn into the transfer case and bottom of the car. Banging on it with an 8' bar didn't even phase it. I could drop the transfer case, but then I'd have to disconnect the drive shaft, which would mean dropping the exhaust. A special tool was the only option. BMW makes a special tool that is also used on the X5, but it's $500 and a week's shipping. I had to make my own.

Here's what I started with.



Here was the finished product (many many hours later). The principle is the same as the homemade subframe bushing tools out there.



Tool in action.





It took about 3 hours to get the tool assembled above the tight confines of the exhaust and push the bushing out. It got it about 3/4s of the way before I ran out of space, but I was able to pry it out the rest of the way with a 3/8" ratchet handle.

New and old bushings.



Now I had to get the new bushing in. Soapy water and forcing it in with hands and pri bars didn't phase it. A new tool would have to be made. I borrowed a piece from my homemade subframe bushing tool and JB welded (I need a welder so bad) a back plate that would press against the irregular surface of the transfer case so I could press the bushing in perpendicular and not at an angle. Here's the tool in action.







The bushing went in a lot quicker than the old one came out. Finally done after investing 2 days of my life. I cannot wait to get a 4 post lift and a welder.



__________________
Cloudbase is offline   Reply With Quote
Ads by Google

Guests, get your FREE E46Fanatics.com membership to remove this ad.
Old 02-21-2013, 10:12 AM   #2
SamDoe1
Registered User
 
Join Date: Oct 2010
Location: Minnesnowta
Posts: 3,479
My Ride: Clubs baby seals


So when I can we all borrow your tool?

Also, pics of the M Coupe.
SamDoe1 is online now   Reply With Quote
Old 02-21-2013, 02:50 PM   #3
jeepo23
Registered User
 
Join Date: Oct 2011
Location: cdn
Posts: 1,078
My Ride: 02 330
Quote:
Originally Posted by SamDoe1 View Post


So when I can we all borrow your tool?

Also, pics of the M Coupe.
I call dibs on the tool as I already msged him

But sweet work on that, I plan on doing mine in a couple of months.
jeepo23 is offline   Reply With Quote
Old 02-21-2013, 09:40 PM   #4
Cloudbase
Registered User
 
Join Date: Apr 2009
Location: Superior, CO
Posts: 65
My Ride: M Coupe, 325xiT
Jeepo23, got your PM, but figured I'd respond here to minimize the repetition.

Unfortunately, the threads on my tool got a little damaged on the extraction and I don't have time to make another one. Plus I drilled my center hole slightly crooked, which made it suck in lining it up. I'm still trying to solve the creaking up front and I have an M Roadster track car that needs lots of attention before the season begins.

Here's what you need to make one:

3/8" All thread. I used a 2' length with quite a bit left over.
Grade 8 3/8" washers. Lots of them.
Grade 8 washer's of varying diameters. I found a 2.5" one that worked perfect. A cast iron pipe end will work too if you drill a hole in it. You can use a larger cast iron pipe end to push the new bushing in.
Steel plates.
5/16 drill, use WD-40 to lube it when you drill the metal.
3/8" tap.

I couldn't drop my exhaust, but I would recommend it if possible. The time you'll save is worth the expenditure. I disconnected mine from the car at the rear hangers and lowered it (supporting it with a jack). Once you drop the carrier, measure your holes with a sharpie and it should work. The pics should help too. I didn't have the room to cut out the old bushing and was nervous I would nick the hole it goes into in the transfer case.

M Coupe Pics...







W/ KW V3's compared to stock ride in Sig



With it's convertible twin

__________________
Cloudbase is offline   Reply With Quote
Old 02-22-2013, 09:11 AM   #5
SamDoe1
Registered User
 
Join Date: Oct 2010
Location: Minnesnowta
Posts: 3,479
My Ride: Clubs baby seals
Quote:
Originally Posted by Cloudbase View Post
M Coupe Pics...


Any reason why you track the roadster and not the other way around?
SamDoe1 is online now   Reply With Quote
Old 02-22-2013, 12:56 PM   #6
Cloudbase
Registered User
 
Join Date: Apr 2009
Location: Superior, CO
Posts: 65
My Ride: M Coupe, 325xiT
I track them both, but the M Roady is much more dedicated. The Coupe is a much better platform and the S54 sings on the on track, but it is #498 out of 690 S54 M Coupes and would be hard to replace if I shunted it. I was looking at E30 and E36 track cars, but came across a local S52 M roadster that was already built. I DD an E30, so the suspension commonality between all 3 cars and parts interchangeability made it a no-brainer. Also, I actually prefer the S52 on the track even though it doesn't have the S54's top end. The S52 throttle cable vs S54 throttle by wire makes a huge difference in shifting for me. Both cars are nearly even (within 3 seconds) at my home track. I'm thinking with a M50 manifold and more aero on the Roady it will be faster.
__________________
Cloudbase is offline   Reply With Quote
Old 02-23-2013, 07:36 PM   #7
redbull 325is
Registered User
 
Join Date: Jul 2006
Location: NC
Posts: 699
My Ride: 325xit/6
Send a message via AIM to redbull 325is
i did mine today, came out pretty quick with a sawzall and a hammer :-D
__________________
Royal Elite Club of 6 Speed Tourings - founder
redbull 325is is offline   Reply With Quote
Old 02-23-2013, 10:56 PM   #8
jeepo23
Registered User
 
Join Date: Oct 2011
Location: cdn
Posts: 1,078
My Ride: 02 330
Quote:
Originally Posted by redbull 325is View Post
i did mine today, came out pretty quick with a sawzall and a hammer :-D
How did you get the new one in?

What sort of symptoms where you seeing and what was the improvement now with this bushing?
__________________
** Removed **
jeepo23 is offline   Reply With Quote
Reply

Thread Tools Search this Thread
Search this Thread:

Advanced Search
Display Modes Rate This Thread
Rate This Thread:

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On
Censor is ON





All times are GMT -5. The time now is 05:36 AM.


Powered by vBulletin® Version 3.8.7
Copyright ©2000 - 2014, vBulletin Solutions, Inc.
(c) 1999 - 2011 performanceIX Inc - privacy policy - terms of use