Be CAUTIOUS with this 'drill and press in a roll pin idea! Splines provide a necessary slip joint! The transfer case is stationary, the front axle is suspended, so when you hit a bump it goes up, and the splines allow the drive shaft to freely slide in and out when the front axle moves up and down (closer and farther from the transfer case). You'll break something else more expensive to fix, like a front differential. Don't do it.
The front axle will come out without removing the transfer case that part is quite easy and you shouldn't have to do any grinding. I'm sure there is no damage to your transfer case either. I fixed mine by installing bushings at the flex plate to drive the axle back into the transfer case deeper where the good threads are. I've had it like that for 8 months now without any problems but I'm still gonna buy the longer axle just to make sure I don't end up stranded out on the interstate oneday! somewhere.
thanks for the posted keep coming. I got a stupid question 03 x5 3.0...the front differential took a went. The suv right now won't go forward or reverse. I can feel the front differential is holding it..I can't get the nuts on the drive shaft out...can I cut off the front driveshaft so I can move the car..since the front differential ain't good. Do I need to look at other things in the car that could have went bad cuz of this issue
My idea was a little more hillbilly, I cut the splined end off about 10 inches back on the drive shaft. Then made 2 round quarter inch steel plates, welded the plates to both cut ends of the drive shaft, drilled holes then welded the splined end to the output shaft of the t case and bolted it together.. the weld has not broke yet neither have the grade 8 bolts..
how do i test the transfercase. reason i ask is because my X5 3.0 will not move forward or reverse. i only hear like a wining/spinnin sound when i put it in reverse or drive
It is likely stripped in the area described. With parking brake engaged and wheel blocked, have someone put into gear. Any gear will work and crawl under. If you see the flange where the front driveshaft goes in is spinning but the shaft isn't it is stripped. A broken chain can also cause this type of noise and issue, but that is pretty rare.
I have a 2001 x5 that the Front drive shaft stripped ,I repaired with a longer one 4 years ago and guess what it stripped agine I don't want to take it out agine like You I don't want to do it agine either so what if I just weld the drive shaft to the transfer case gear ?? with a nice bead around the female end?? My buddy says its needs to move I say who cares weld it up if it stripps agine??
While it does not move..... mine did the same thing in the end. I then had it welded. Lasted about 200 miles and broke again. Now my real problem was that the guibo/flex coupler at the other end was shot and that is what causes the wobble and it to strip out. Had to replace my whole transfer case and driveshaft. Installed anew flex joint at the front differential end and no more issues.
The splined slip joint is necessary, that's why it's there. Weld it and you'll be replacing your front differential. Suspension moves up and down, transfer case is stationary. My feeling is a '1 inch longer' driveshaft is not enough. I'm going to weld my 'nose only' repair kit longer, like 1.5 to 1.75 inches longer IF the dust cover clears. I've already removed my transfer case, it's not that bad. You can take the t-fer case cross member without removing the exhaust - just carefully put a 5/8" socket on an extension thru the twin pipes and the heat shield. You don't have to remove the entire transfer case, just loosen the star bolts and slide it back a half inch.
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Be CAUTIOUS with this 'drill and press in a roll pin idea! Splines provide a necessary slip joint! The transfer case is stationary, the front axle is suspended, so when you hit a bump it goes up, and the splines allow the drive shaft to freely slide in and out when the front axle moves up and down (closer and farther from the transfer case). You'll break something else more expensive to fix, like a front differential. Don't do it.
The front axle will come out without removing the transfer case that part is quite easy and you shouldn't have to do any grinding. I'm sure there is no damage to your transfer case either. I fixed mine by installing bushings at the flex plate to drive the axle back into the transfer case deeper where the good threads are. I've had it like that for 8 months now without any problems but I'm still gonna buy the longer axle just to make sure I don't end up stranded out on the interstate oneday! somewhere.
furry fuzzy434 did u use like washers or what exactly did u use to extend your drive shaft cause I was thinking about doing the same thing
LMAO THIS is automotive comedy
Hell yea,,, thanks...
God idea
Good idea 👍🏽👍🏽👍🏽
thanks for the posted keep coming. I got a stupid question 03 x5 3.0...the front differential took a went. The suv right now won't go forward or reverse. I can feel the front differential is holding it..I can't get the nuts on the drive shaft out...can I cut off the front driveshaft so I can move the car..since the front differential ain't good. Do I need to look at other things in the car that could have went bad cuz of this issue
My idea was a little more hillbilly, I cut the splined end off about 10 inches back on the drive shaft. Then made 2 round quarter inch steel plates, welded the plates to both cut ends of the drive shaft, drilled holes then welded the splined end to the output shaft of the t case and bolted it together.. the weld has not broke yet neither have the grade 8 bolts..
Can you explain this a little better I’m interested
When it makes a popping noise moving forward. I change out the CV axles already but that noise is coming from the driveshaft.
You may have a stretched chain in your transfer case. That makes a pop sound too and is a common failing. There are a few videos of how to replace.
Ok appreciate it.
how do i test the transfercase. reason i ask is because my X5 3.0 will not move forward or reverse. i only hear like a wining/spinnin sound when i put it in reverse or drive
It is likely stripped in the area described. With parking brake engaged and wheel blocked, have someone put into gear. Any gear will work and crawl under. If you see the flange where the front driveshaft goes in is spinning but the shaft isn't it is stripped. A broken chain can also cause this type of noise and issue, but that is pretty rare.
Hi my front shaft is turning but after about 10 meters of driving it looses gear. no front or reverse gear. do you any suggestions? Thanks
I have a 2001 x5 that the Front drive shaft stripped ,I repaired with a longer one 4 years ago and guess what it stripped agine I don't want to take it out agine like You I don't want to do it agine either so what if I just weld the drive shaft to the transfer case gear ?? with a nice bead around the female end?? My buddy says its needs to move I say who cares weld it up if it stripps agine??
While it does not move..... mine did the same thing in the end. I then had it welded. Lasted about 200 miles and broke again. Now my real problem was that the guibo/flex coupler at the other end was shot and that is what causes the wobble and it to strip out. Had to replace my whole transfer case and driveshaft. Installed anew flex joint at the front differential end and no more issues.
The splined slip joint is necessary, that's why it's there. Weld it and you'll be replacing your front differential. Suspension moves up and down, transfer case is stationary. My feeling is a '1 inch longer' driveshaft is not enough. I'm going to weld my 'nose only' repair kit longer, like 1.5 to 1.75 inches longer IF the dust cover clears. I've already removed my transfer case, it's not that bad. You can take the t-fer case cross member without removing the exhaust - just carefully put a 5/8" socket on an extension thru the twin pipes and the heat shield. You don't have to remove the entire transfer case, just loosen the star bolts and slide it back a half inch.
So when the front drive shaft goes you lose rear wheel drive too?
Yes
did you also lose reverse gear?