325ix Transfer Case Woes

[mph]

Alright, a while back, my car inhaled some water and the engine was hydrolocked. I had the engine rebuilt and on the day I got the car back, it slowly started to make a clunking noise from what I thought was the rear end and it was only on hard acceleration. The mechanic who did the work said it seems like a bad bushing and to not beat on the car until I could get it back in to him to have it looked at again.

After a little more driving, the clunking started to happen all the time on startup through the torque band.

Today, we pin-pointed the noise. The noise is coming from the transfer case. We opened the fill hole and found it was completely empty! We filled it back up to the level is should be at and the noise hasn't gone away. I drove the car 50 miles back to school.

My question for you guys is about the design of the transfer case. I know in other manufacturers designs, the transfer cases have a vent at the top. I need to know if it is possible in the BMW design for it to take on water if fully submerged. The insurance company covered everything fot the engine to be rebuilt and I'm hoping this isn't just a coincidence and was caused from the water.

A little more info: Before I bought the car, the previous owner had the transfer case opened and resealed with new gaskets and seals. I know for a fact it was full of fluid and it hasn't dripped a drop on the driveway. It leaks no fluids. Since when I bought the car, I put 16k on it.

[nando]

your chain is fucked. driving with a dry tcase will do this (the pins will wear and cause the chain to stretch, making it skip teeth).

it's possible that the water got in there, and yes there is a vent, but I have no idea if your flood caused it. leaking tcases are common and people seem to not understand that they must be checked on regularily.

[mph]

I need to know if this could have been caused from the flood damage though? Thats my biggest question. Do you know if they have a vent on the top that water could have entered?

[nando]

yeah sorry, didn't see that part of your post.

[mph]

Do you have access to any diagrams of the transfer case that show the vent? Also, do you know of any reputable sources that have a similar situation?

[Dave]

Do you have access to any diagrams of the transfer case that show the vent? Also, do you know of any reputable sources that have a similar situation?

Are you a member of the 325ix SIG? That is where I'd ask. Those guys know alot. Or email Jenny Morgan who does the column every month in Roundel. She is an iX guru.

[mph]

Are you a member of the 325ix SIG? That is where I'd ask. Those guys know alot. Or email Jenny Morgan who does the column every month in Roundel. She is an iX guru.

What you talkin' bout Willis?

[Dave]

Are you a member of the 325ix SIG? That is where I'd ask. Those guys know alot. Or email Jenny Morgan who does the column every month in Roundel. She is an iX guru.

What you talkin' bout Willis?

http://home.earthlink.net/~wardellhix/iX/

All iX, all the time. They have a Yahoo Group and there is a lot of iX info there.

Jenny Morgan used to own a garage up in Wisconsin or Minnesota and writes a column in Roundel every month. jmorgan@roundel.org. If you are a CCA member, you should recognize her name.

[nando]

http://groups.yahoo.com/group/thebmw325ixclub/

I don't have a diagram, but I know the vent is on top of the transfer case. I've never heard of anyone having theirs flooded but I do know that if you run the tcase dry it will fuck it up quickly...

[mph]

Yeah, I know it will fuck it up if its ran dry, but I'm really concerned with the flooding issue and what will happen if it is fully submerged in water. I know for a fact it can happen with a transmission because a friend of mine had their car in the same water mine was in and the engine and the tranny needed to be rebuilt as a result. The transmissions also have a vent on the top of them, just like the transfer case.

[mph]

Does anyone have any pictures of the transfer case or a diagram that shows the vent on the top?

Also, does anyone know of a similar event that caused problems with a transfer case in another car, not just a BMW?

[DanGillan]

even if it was submerged in water, that wouldnt cause all the oil to miraculously dissapear. poor maintenence. suck it up and fix your mistake. dont waste everyone elses money claiming from insurance.

[mph]

even if it was submerged in water, that wouldnt cause all the oil to miraculously dissapear. poor maintenence. suck it up and fix your mistake. dont waste everyone elses money claiming from insurance.

What the fuck are you talking about man? The case was submerged in water. Water entered the case through the vent and mixed with the ATF fluid. Over the period of the five days I had the car back from having the engine rebuilt, the water mixed with the fluid and escaped through the seal. I did a whole ton of research and this happens in a lot of all wheel drive cars, not just BMW's. The samething happens with transmissions. The transfercase is considered an 'auxiliary transmission.'

And I don't know what the hell you're talking about with the whole insurance claim crap. I pay for my insurance to cover these things. I'm going to make a claim when its something they will cover. Thats why I pay for it. I'm also pretty sure me making a claim isn't going to make anyone elses insurance rates increase. Theres plenty of other things that will do this for you, i.e. hurricanes.

None the less, I was able to find a replacement transfercase from the dealer. They're ordering it from a BMW warehouse in Germany for a cost of $2200. It's a genuine BMW part that was remanufactured by them. Insurance company is picking it up for me:)