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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 05-08-2020, 04:09 AM   #1
darkfires102
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Transfer Case Washers

Doing the whole driveline fluid change this weekend...Ordered washers for the diffs and ended up forgetting washers for the tcase ...Has anyone not replaced the washers and got away with it? Im losing my mind over it. Thought it was just like the manual tranny with no washer.
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Old 05-08-2020, 12:44 PM   #2
Rtcoleman
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I've always replaced, so can't help with reuse, but they ought to be available on the shelf at a dealer. They're used in cars as recently as 2018 according to realoem.

I might also have an extra or two, let me check later tonight.
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Old 05-08-2020, 11:58 PM   #3
jmo69
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I never buy new washers, no problems.
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Old 05-09-2020, 12:10 AM   #4
darkfires102
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Originally Posted by Rtcoleman View Post
I've always replaced, so can't help with reuse, but they ought to be available on the shelf at a dealer. They're used in cars as recently as 2018 according to realoem.

I might also have an extra or two, let me check later tonight.
I heard its the same washer as the oil drain plug, which in that case I have extras. If not...Im gonna just flip it around. I pray to god this thing doesnt leak because if it does the tcase is gonna blow since it holds so little fluid
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Old 05-09-2020, 12:11 AM   #5
darkfires102
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I never buy new washers, no problems.
So youve never replaced the washers on the diffs or tcase? Did you just flip them around?
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Old 05-09-2020, 10:38 AM   #6
Rtcoleman
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I don't have any transfer case gaskets. They are Cu, but bigger than the oil drain gaskets, so no luck there either.

I do have 5(?!) of the old front and rear diff gaskets though - who knows why.

FWIW I always buy new gaskets. I'm picky, plus never have a good feeling about the burr from where it gets mashed into the hole.
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Old 05-09-2020, 06:15 PM   #7
darkfires102
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I ended up changing all fluids in the car, engine oil + filter, power steering , both front and rear diffs, tcase and manual tranny. I reused the copper tcase washers. New washers for the diffs.
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Old 05-09-2020, 06:22 PM   #8
darkfires102
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Just a tip for anyone gearing up to do this buy the redline kit off of turner's site, its like 60 bucks for all of it, make sure to add the washers you need aswell. I went against their recommendation of using D4 in the tcase and tranny and im happy. Diff fluid is barely enough to fill both, I nearly **** myself when the bottle ran empty on filling the front diff...Maybe add on an extra bottle if you're reckless. I added on a bottle of MTL for like 16 dollars and filled the tcase and tranny with that. Tcase fluid was absolutely disgusting, I kept the drain plug off and filled it with MTL to wash out the old fluid till it ran out clean, and had only half the bottle left for the tranny, so I did a mix of D4 ATF and MTL. Both my diff fluids seemed to been changed before by a PO but the tcase and transmission fluid were real bad, and the transmission fill and drain bolts were nearly impossible to break loose, so im assuming those two were original fluid. I'm keeping the spare bottle and a half for power steering fluid now. All redline fluids in this car except for the oil which is mobil 1 0w-40.
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Old 05-09-2020, 10:09 PM   #9
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So youve never replaced the washers on the diffs or tcase? Did you just flip them around?
I might have flipped them but it's been a while for the front dif and T-case. T-case is due, I'll do that once I have my e36 drivers seat finished and insured.
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Old 05-10-2020, 09:50 AM   #10
77'911
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Depends who been there before you. I order them when it strikes me. Having said that, I just did all the drive line fluids recently without changing the afore mentioned items without issue. If your concerned, NAPA usually the alu washers. Here's the oils I used:
1) Transfer case, BMW Group, SAE 75w-80, MTF-LT-2 , pt# 83 22 2 339 219 , used about 200-300 ml of the liter
2) rear & front diff, BMW Group, SAE 75w-90, Final Drive Gear Oil, C-SAF-XO, pt# 07 51 2 293 972, used about 2 liters for both
Since we have an auto gearbox, I changed/serviced that out but that belongs on a different thread. ; )
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Old 05-13-2020, 12:31 AM   #11
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Dark,

How many miles on yours? Thanks in advance for the head's up. I have way too many diffs to service in my fleet and often reuse. If something's got a lip, I'll reflatten it with a piece of sandpaper glued to a piece of marble I keep around. I think the process for doing this is called lapping and it's pretty quick with these copper/aluminum soft metal washers. However, it is always wise to have a couple new ones around with a sharpie marked "E46 oil pan" for the one day several changes from now when it is bunged up. It's a point worth making that you won't know it's the day you finally have to replace it until the oil's drained and its in your hand and it's a weekend, right? So take chances, but always have a back up plan I say...
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Old 05-16-2020, 04:01 AM   #12
darkfires102
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Dark,

How many miles on yours? Thanks in advance for the head's up. I have way too many diffs to service in my fleet and often reuse. If something's got a lip, I'll reflatten it with a piece of sandpaper glued to a piece of marble I keep around. I think the process for doing this is called lapping and it's pretty quick with these copper/aluminum soft metal washers. However, it is always wise to have a couple new ones around with a sharpie marked "E46 oil pan" for the one day several changes from now when it is bunged up. It's a point worth making that you won't know it's the day you finally have to replace it until the oil's drained and its in your hand and it's a weekend, right? So take chances, but always have a back up plan I say...
Just crossed over to 144k today. Rear diff fluid seemed pretty fresh, golden color. Tcase and tranny fluid were definitely original, front diff seemed like it was serviced long ago.
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