BMW transfer case actuator worm gear replacement

A How-To video of a simple disassembly, worn part removal, replacement part install and reassembly of a transfer case actuator.
Replacement Gear available on eBay:
www.ebay.com/itm/Bmw-Transfer...
Worm Gear Replacement Kit on eBay:
www.ebay.com/itm/6pc-Kit-Bmw-...

[@daleeckert9420]

My new to me 07 328XI had the grinding sound on startup. Lights galore on the dash 4x4 and such. Several faults stored which would not clear. Pulled the motor and opened it up. The gear was shot and looked just like the one in the video. Installed the kit and cleared faults. Viola problem solved. Just make sure you reset the system if you replace the resistor that comes in the kit. I also changed the transfer case fluid since I didn't know if it was ever done. Saved me a lot of time and money as we were going to just install a used transfer case. Many thanks for this kit and answering any questions I had during the gear installation.

[@TalonZ33]

I have the same exact car and the same issue. I've already gotten a new T.case motor (gonna rebuild old one for back up) I plan on doing it myself and I'm wondering what exactly do you mean by "Reset System" ? Is it gonna require a high end scanner to do?

[@Justdoit000]

Jerry. Thank you so much for your product. I had 4x4 AWD, DSC, Brake, EMERG EBV lights were on on my 2008 BMW 535xi and replacing this fixed the problem. People like you deserve lot of credit. I went from buying a new transfer case ($400) to $60 and couple of hours of do it yourself project. (His product is listed on ebay) Thanks again my friend.

[@TheBrakelyn]

Hello Jerry, where can i find the replacement gear and gear replacement kit? The eBay links that you posted on the comment section do not work..

[@TheSteelheadKiller]

GENIUS, thanks for sharing.

[@msp116ful]

Hi Jerry, between you and E90 post you guys have saved ALOT of people a Shitload of money...many thankS...now where can I get one???

[@jerrywhitmer1483]

Anytime the eBay listings for these parts doesn't show any parts available, it means one of 2 things. Either I'm waiting to receive more stock or I just haven't had a chance to relist it. It might take up to a week to relist the 6pc kits because some of the pieces that I order haven't made it in yet. But it shouldn't take more than a couple days at the most for the worm gears.

[@Pislui]

what kind of grease you use after you clean the gear pack?

[@hxtubehx]

Jerry, what is the actuator motor part number for the one that you made the worm gear for? I have a 2008 535xi and the transfer case actuator motor part number is BMW OEM 7546671. Wanted to know if the gear works for mine. Been having the triad of lights for a while. Thanks.

[@xarli24]

Hi Jerry, I'm in France and I'm going to order worm gear, the thing is that I've never saw a gear puller tool like yours. Where can I found the same ? Merci Charlie

[@jerrywhitmer1483]

The mating gear for these worm gears is metal. The nylon gears are in the actuators used in the SUVs. These worm gears are only for the AWD cars.

[@Tracyspellenberg]

Jerry I know this was posted a while ago but I'm trying to troubleshoot no voltage 2 kl30. Basically saying no power to transfer case all fuses are good would it be a dead Actuator motor?

[@chawenhalo0089]

Hello Jerry. Great video and well done for machining this part. Question: has this fix actually held up and for how long. As far as I know the ATC300 was (wrongly) made to work in the E90 / E60 BMW not considering DCT and ABS activation which has resulted in a much shorter lifecycle of the entire transfer box. A manufacturer rep explained to me that once you start to hear a sound underneath the car its just a matter of time before the entire box lets go. Changing the servo motor actuator or just the worm gear isn't going to change much down the line...

[@jerrywhitmer1483]

ChawenHalo 008 thanks for the feedback. Yes, the worm gear replacement corrected the issue.

[@IliyaUzunovgp]

Hello Jerry, Thank you for the wonderful video and for listing that part. I also got the 4x4, DSC,ABS and EBV failure on my dashboard. I am about to order two kits, just in case I need to share one with a friend. The thing is that the mating gear ( 5:28 ) has a little wear and I would very much like to replace that as well. Would you happen to have that part or can you tell me where can I find it?

[@jerrywhitmer1483]

Hi Iliya, Sorry for the delayed response. I had planned on making the mating gear, but haven't come across one that was worn enough. If you have one that is exceptionally bad, I can see what I can do to get one to you. Message me on eBay. Search for cncskater :-) -Jerry Whitmer

[@canadac3601]

Where can I get that worm gear?

[@peterjg001]

Hi Jerry, do you still sell these? My e92 335i x drive is throwing some transfer case codes, I want to buy this and change it before my t case gives out

[@soler233]

Before I order it I will like your opinion on my problem I have 2008 535xi and two days ago my abs 4✖️4 and break light came and I'm get and engine check light code U1126 must ppl said replacing this gear will solve the problem plz let me know if that's the case

[@jerrywhitmer1483]

+mohamed diallo I'm not sure about the U1126 code. There are 2 main causes for those lights to come on. Either the actuator motor isn't working anymore or the motor is working but the gear is worn away enough to not move the mating gear. If you can hear the fast clicking sound of the gear teeth missing right after you start the car, the gear is the problem.

[@RaBluPhi1]

Does the actuator gear fit in a 2006 330xi manual?

[@jerrywhitmer1483]

Hi Ry Yes. This worm gear fits your 2006 330xi stick shift :-)

[@kellenyoung7441]

What if a mechanic tells me that the actual actuator motor is dead or bad? The motor itself, not just the gear.

[@soler233]

I have the same problem right and can find that gear the one on eBay is gone

[@jerrywhitmer1483]

+mohamed diallo If you click on the "view relisted item" it will take you to the updated eBay listing.

[@godla26]

Hi Jerry Are going to have more of these gears for sale? Thank you

[@jerrywhitmer1483]

Hi. I updated the link. Now it will go to the current listing.

[@rickridgeway905]

Jerry, I was looking for a video on replacing the entire assembly when I saw your video, once I pull it out and confirm it is the worm gear, I will order your ebay part. Save me over $200. Questions..how did you figure out where to cut to expose the shaft, by just cutting a bit at a time? And can you recommend a good grease to use inside? And, how did you learn how to machine a worm gear? I can barely use a hack saw..

[@rickridgeway905]

yes, worm gear is shot. Your link shows sold. Are you still producing these parts?

[@jerrywhitmer1483]

Sorry for the delayed response. I usually only use my phone to relist the worm gears on eBay so the link doesn't often get updated. I will do that now. I use moly-dee grease, there might be something better though. It took a little while but just a little reverse engineering :-)

[@cutesteva1328]

Hi, do still have the worn gear for sale i search on ebay and nothing came out.

[@jerrywhitmer1483]

Hi yes. Here is the link: www.ebay.com/i/162685643135

[@cutesteva1328]

Jerry Whitmer question i open my motor and its good so my problem is not the gear so far i try buying an used one still dint work my light stays on what else should i look for i came across that it could also be the steering wheel sensor that is bad to reset it, could that be faulty? Cuz when i turn the signal light and i turn they wont turn off. This came light came out after my belt broke and battery died belt has been replace and battery good

[@jerrywhitmer1483]

Based on the fact that your turning light doesn't turn itself off after a turn, I agree that there's an issue with the steering angle sensor.

[@synonomaus4434]

Where can you buy the individual parts for this? It would be very helpful to have part numbers for the gears, o-rings, etc, - or just a source to order them.

[@jerrywhitmer1483]

+Synono Maus for some reason the eBay address changes each time I relist and I forgot to update the link. its updated now. thanks :-)

[@brandonfargo5154]

Jerry Whitmer

[@brandonfargo5154]

Jerry Whitmer hi jerry. do you no if the other gear is available? the nylon gear that mates to your worm gear I just got looks a bit worn. thank you

[@deneeforbes4352]

Haha!

[@arturasbarysas1093]

Hi.How i can buy worm gear?

[@jerrywhitmer1483]

Hi. The worm gears are available on eBay. Just search for "BMW worm gear"

[@danadetweiler1231]

So i did find the worm gar on ebay and now we have the unit out and apart, the worm gear is worn very thin in the middle and the plastic gear is about disinegrated is that plastic gear available. you show yours to be intact.

[@danadetweiler1231]

nevermind tech misinformed me

[@soler233]

I'm hearing a little clicking sound