[jrx322]

Hi all,

I've read through lots of different posts about this issue but I'm struggling. My situation is as follows.

I recently purchased a 2007 BMW x3 E83 2.0d and during the test drive missed a clunking noise which appears when turning the car at low speeds, normally at about 2/3 full lock. The car also feels a bit like it's going to stall.

I disconnected the fuse that controls the transfer box actuator and the problem disappears so definitely related to the front section of the drivetrain.

After reading up on the issue, I've done the following:

1. Checked all tyres of are the same size/make/wear. All are dunlop SP sport star rated with similar tread. They are different sizes but I think this is expected on a staggered setup (msport).
2. Drained and replaced transfer case oil. The oil was moderately brown but no metal shavings to be seen.
3. Removed the actuator and replaced the gear, looked like the gear had been replaced already only slight signs of wear (slightly bent fins).
4. Ran calibrations via ISTA for oil change and actuator repair.

Running diagnostics this morning returned the following error code:

54C4 - calibration faulty

I then had the triad of lights which are no longer showing and the following error codes in diagnostics:

539E: VTG: Transfer case: Malfunction
5F3A: DSC Transfer Case: Malfunction

Is it likely that the transfer case is shot?

Any other thoughts on what I can do without throwing loads of money at it?

[bartolio]

Did you ever figure this out? Sound like the exact problem I have.