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      06-25-2012, 09:35 PM   #1
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Angry AWD Malfunction...4X4,ABS,EBV EBRAK,DCS...FIXED! See Post #21

FIXED: http://www.e90post.com/forums/showpo...1&postcount=21

Well yesterday morning i get up wash my car all clean and then i let it dry up and then i'm ready to go take a drive upstate with one of my friends. Fire the car up, drive around the block and out of no where i get all these codes!! Cleared the codes then took another drive around same thing again...So idk wtf it is, seems like i've been talking about the TC lately alot and it finally gave up on me. All mods on sig, wasnt pushing the car really the past few weeks or so...This just happend out the blue...

Codes/Faults:

Quote:
MSD80/MSD81 Engine module for N53/N54

Current Fault Codes


2D25:
2D25 manipulation cover, maximum air mass
Error will not cause a warning light
Error is not currently present
Test conditions have been completed
Short circuit or signal interruption


Dynamic stability control DXC8 Plus - E90

Current Fault Codes
5F12:
Brake pad wear: Front axle wear limit reached.
Error will cause a warning light
Error is not currently present
Test conditions have been completed


5F3A:
Clutch gearbox-ECU: VG-clutch defective - clutch is open - rear wheel drive!
Error will cause a warning light
Error is currently present
Test conditions have been completed



Dynamic stability control DSC 87


Current Fault Codes
5F12:

Error will cause a warning light
Error is not currently present
Test conditions have been completed


5F3A:

Error will cause a warning light
Error is currently present
Test conditions have been completed

Gearbox control unit

Current Fault Codes
51B0:
DSC Signal not plausible: Brake pressure signal
Error will not cause a warning light
Error is currently present
Test conditions have been completed


Transmission distribution module

Current Fault Codes
5462:
5462 Error actuator or increased power requirements fpr clutch
Error will not cause a warning light
Error is not currently present
Test conditions have not been completed


5463:
5463 Break mechanics
Error will not cause a warning light
Error is not currently present
Test conditions have not been completed


55C3:
55C3 VGSG-all-wheel-Notlaufregelung activated. No DXC index moment requirement.
Error will not cause a warning light
Error is not currently present
Test conditions have not been completed


539E:
539E Function error VTG hole system
Error will not cause a warning light
Error is not currently present
Test conditions have not been completed
I've about had it with this AWD bs. Will take it somewhere probably tommorrow to have it checked at and well see what it is...
Out of warranty so will see how much they quote me and whats the issue..

THE FIX.......Edited my post to show here and also my original post on post #21.

Okay, so i Replaced the Servo Motor / Set Positioning Motor and i decided to open up the old one to see what broke, The motor/gears inside were all lubed up properly I just cleaned it to be able to see what was broken and also there were bunch of plastic on the gears from the chewed up part you see in the pic...See pictures Below.
I got the Servo Motor from Tomkinsonbmwparts.com Cheapest i've found $423.00
Part# 27 10 7 546 671

Also had to Replace the Transfercase Support Mount, it cracked and it was all wobbly so i had to replaced it, what caused this i have no clue!!!
I got this from Turner Motorsports, cheapest i've found!
Part #: 22316773125 (22-31-6-773-125) $47.00
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Last edited by BES335xi; 09-05-2012 at 01:23 PM.
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      06-26-2012, 12:29 AM   #2
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I had the same codes, was the Servo Motor for the TC. Part #27107546671, bout $750.
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      06-26-2012, 08:48 AM   #3
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Originally Posted by Rob.K View Post
I had the same codes, was the Servo Motor for the TC. Part #27107546671, bout $750.
Wow Thanks, Thats pricey!...Thanks for the info.

EDIT: Just checked all the online sites, and Tischer has it at $483.27
Still pricey! Well see if that happends to be it, and will update.
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      06-26-2012, 11:26 AM   #4
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Yup, took it down the block to a shop and they said its the Servo Motor "Gearing" the motor its self said is fine, from what they tested but the gearing is bad so they said...They quoted me $650 for the Motor, i paid diag fee and took my car. Will get a new motor from tischer at $484 and will replace the whole thing..

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      06-26-2012, 11:38 AM   #5
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Sometimes I hate being right

From this thread:

http://www.e90post.com/forums/showthread.php?t=708132

"Documented failures of x-drive transfer cases seem to all stem from the worm gear/cog interface (x3's, typically). The main reason is that the cog is a plastic gear that isn't intended to take large loads. The secondary reason is that through normal driving, the cog/worm gear will only cycle through a very narrow range. As such, it is my feeling that this is the first point of failure."
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      06-26-2012, 12:16 PM   #6
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Quote:
Originally Posted by Doyle View Post
Sometimes I hate being right

From this thread:

http://www.e90post.com/forums/showthread.php?t=708132

"Documented failures of x-drive transfer cases seem to all stem from the worm gear/cog interface (x3's, typically). The main reason is that the cog is a plastic gear that isn't intended to take large loads. The secondary reason is that through normal driving, the cog/worm gear will only cycle through a very narrow range. As such, it is my feeling that this is the first point of failure."
Yup, And lately i've been worrying about it so much that now it happened to me, lol Funny. I'm going to buy the Servo Motor and either try and replace it my self or just take it somewhere local to change it and while i'm in there change the tcase fluid aswell..

Anyone has a bentley manual or any info if you need to do any coding once it is replaced?
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      06-26-2012, 12:47 PM   #7
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Quote:
Originally Posted by Doyle
Sometimes I hate being right

From this thread:

http://www.e90post.com/forums/showthread.php?t=708132

"Documented failures of x-drive transfer cases seem to all stem from the worm gear/cog interface (x3's, typically). The main reason is that the cog is a plastic gear that isn't intended to take large loads. The secondary reason is that through normal driving, the cog/worm gear will only cycle through a very narrow range. As such, it is my feeling that this is the first point of failure."
Well played.



You are right quite a bit my good man. We like having you around for that so dont go anywhere!
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      06-26-2012, 12:50 PM   #8
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Would there be enough of an advantage to have a cog built to the same specs from a stronger material than is presently used?
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      06-26-2012, 01:17 PM   #9
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Would there be enough of an advantage to have a cog built to the same specs from a stronger material than is presently used?
Apparently the X3 guys have found a fix that will last you a few months by turning the gear 180deg. And there was also a guy there that supposed to have one machined or whatever that will last longer and stronger.

From this forum/posts: http://www.bimmerfest.com/forums/sho...d.php?t=566880

The guys website: http://www.odometergears.com/

Would be nice if any of you technical guys that know much about this to get in touch with him/that company and have them work on something for our cars, since this thing is happening around alot and it is becoming more common.

-Looks like i will be getting a new actuator and i will be putting it my self to save some $ and i really need my car since it is the only car i have and i dont want to drive it for too long like this as it could damage something else.
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      06-26-2012, 11:57 PM   #10
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I just emailed odometergears to inquire. I will update you as soon as he responds
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      06-27-2012, 02:08 AM   #11
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I just emailed odometergears to inquire. I will update you as soon as he responds
K, Sounds good.
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      06-27-2012, 09:05 AM   #12
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Quote:
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Well played.



You are right quite a bit my good man. We like having you around for that so dont go anywhere!
The amazing power of google and critical thought!

I'm nothing special ... just an enthusiast that wants to harness the full power of this amazingly capable machine.

If we can get that cog made out of metal, I think that would make the TC borderline bulletproof. Maybe WPC coat the clutch plates, but I think that might only be necessary at extreme power levels.
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      06-27-2012, 04:34 PM   #13
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Quote:
Originally Posted by Doyle
Quote:
Originally Posted by nailer335 View Post
Well played.



You are right quite a bit my good man. We like having you around for that so dont go anywhere!
The amazing power of google and critical thought!

I'm nothing special ... just an enthusiast that wants to harness the full power of this amazingly capable machine.

If we can get that cog made out of metal, I think that would make the TC borderline bulletproof. Maybe WPC coat the clutch plates, but I think that might only be necessary at extreme power levels.
Initiative goes a long way these days, with google in our pockets at our immediate disposal and what not...

No response from odometergears yet. I'd do a metal piece instead of the OEM plastic as soon as possible without waiting to break the OEM cog... just to be able to launch hard worry free.
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      06-27-2012, 06:25 PM   #14
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Quote:
Originally Posted by nailer335 View Post
/
Quote:
Originally Posted by Doyle View Post
/
I will be replacing mine hopefully next week if/when it comes in. Placed an order last night. And i will tear apart my old one to see what happened and will take pictures as maybe there is someone out there that can provide us with better gearing or what not. Stay tuned.

-This will be my last year of owning an XI though, i'm fed up with it. Great car love it, just my car doesnt seem to like too much power.
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      06-27-2012, 09:07 PM   #15
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I received an email from Jeff at odometergears. They are working on an upgrade (he didnt specify) for the ATC300 and the X5 TCs. He said that they are about a month away from releasing these upgrades. He asked me to call him for more info on the TC in the 335xi- he's unaware that the same ATC300 is used in the 335xi that is used in the X3.
I'll call and get more information tomorrow but it looks like we're about a month out from an upgraded TC worm gear / cog interface for our cars
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      06-27-2012, 10:04 PM   #16
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Quote:
Originally Posted by nailer335 View Post
I received an email from Jeff at odometergears. They are working on an upgrade (he didnt specify) for the ATC300 and the X5 TCs. He said that they are about a month away from releasing these upgrades. He asked me to call him for more info on the TC in the 335xi- he's unaware that the same ATC300 is used in the 335xi that is used in the X3.
I'll call and get more information tomorrow but it looks like we're about a month out from an upgraded TC worm gear / cog interface for our cars
Nice, that's great news. Try and keep intouch with him if you can so alot of you others dont have to go through what me and a bunch of others already went through...Also like i said before if he needs pictures of the ATC300 Servo Moto, I'll take some when i take it apart and upload 'em here, But since it's the same servo as the X3's then it no use, and i really should of just tried turning it 180 degrees, instead of driving like this.

Hmm I'll check on my order and if it's more then a week away, i'll probably try and do what the x3 guys did and see if it works..

Thank's nailer & keep us updated.
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      06-28-2012, 01:05 AM   #17
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Pictures couldnt hurt. If nothing else they'll serve educational purposes for others.

I'll call him sometime before the end of the week to get a better idea of what their upgrade entails.
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      06-28-2012, 01:57 AM   #18
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Pictures couldnt hurt. If nothing else they'll serve educational purposes for others.

I'll call him sometime before the end of the week to get a better idea of what their upgrade entails.
Yup thats why i'm planning on tearing it up, to see what happened in there and like you said it could serve educational purpose to others.

Sounds good on that call man, hopefully they make something..Keep us updated.
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      06-28-2012, 07:56 AM   #19
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Quote:
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Yup thats why i'm planning on tearing it up, to see what happened in there and like you said it could serve educational purpose to others.

Sounds good on that call man, hopefully they make something..Keep us updated.
Destructive testing/analysis is exactly what needs to happen.

The good news is that your breakage likely comes more from "wear and tear" than power issues. Unfortunately, with BMW these days it seems like their cars are made out of plastic and US dollars.

Another option (if odometer gears doesn't work out) is Matt Morkin over at b immer b oost dot com. He seems to have access to a quality fab/machine shop and is willing to take on niche projects.
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Last edited by Doyle; 06-28-2012 at 07:58 AM. Reason: e90post tried sneaky censorship
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      06-28-2012, 05:05 PM   #20
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Quote:
Originally Posted by Doyle View Post
Destructive testing/analysis is exactly what needs to happen.

The good news is that your breakage likely comes more from "wear and tear" than power issues. Unfortunately, with BMW these days it seems like their cars are made out of plastic and US dollars.

Another option (if odometer gears doesn't work out) is Matt Morkin over at b immer b oost dot com. He seems to have access to a quality fab/machine shop and is willing to take on niche projects.
You're right about that, The most my car has seen in term of power FBO + 40% E85, and E85 i just started using within the last month or so, It's most likely the stop n go traffic here in NYC that the awd keeps working like an animal day in day out, wonder if I push DTC and put it as Inactive every time i drive would have any effect on the servo or tc as far as taking it easy on them, when driving local.

Yeah Mat would be a great option as well but i dont think that will happen anytime soon as he's very busy with the Mani & the turbo setups he's planning on doing, but maybe in the future..
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      07-17-2012, 11:03 PM   #21
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Okay, so i Replaced the Servo Motor / Set Positioning Motor and i decided to open up the old one to see what broke, The motor/gears inside were all lubed up properly I just cleaned it to be able to see what was broken and also there were bunch of plastic on the gears from the chewed up part you see in the pic...See pictures Below.
I got the Servo Motor from Tomkinsonbmwparts.com Cheapest i've found $423.00
Part# 27 10 7 546 671

Also had to Replace the Transfercase Support Mount, it cracked and it was all wobbly so i had to replaced it, what caused this i have no clue!!!
I got this from Turner Motorsports, cheapest i've found!
Part #: 22316773125 (22-31-6-773-125) $47.00
Attached Images
  
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Last edited by BES335xi; 09-05-2012 at 01:22 PM.
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      07-18-2012, 03:11 PM   #22
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Do you happen to be running a staggered setup with your wheels?
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