[paulv824]

hello I’m recently having a problem with my all-wheel-drive system on my 2007 328xi 6SPD. I have codes 539E and 54c6. I have tried to calibrate the new actuator I have replaced (oem). I keep getting a fault and the calibration fails. I have checked all the fuses none were blown. when I run the test on the actuator there is no noise coming from bottom of the car but I do get a clunking noise when I shut off the car. when the car is on the lift all four wheel spin there is no whining no clunking and no clicking noise signifying a bad transfer case. also at times on a fresh cold start all the lights are off on the dash and after about 30 seconds are driving they all turn on which are the brake light the track control light and the 4 x 4! i’m not too sure if the oil has been replaced before in the transfer case. also would having the wrong fluid inside the transfer case cause these fault codes to appear and Would swapping out the fluid with OEM fluid fix a problem. if anyone has any idea or any other questions please reply I really need to get this car working before winter New Jersey hits. thank you.

[BKV122]

I basically just went through the same issues as you did...swapped the worm gear in my original actuator motor, still no change, then swapped the whole actuator unit with a used one....during the motor swap I looked in the tcase and saw the gear teeth over rotated meaning the tcase was done. Swapped with rebuilt and all is good.
Check this thread out:
https://www.e90post.com/forums/showthread.php?t=1431808

[paulv824]

Originally Posted by BKV122

I basically just went through the same issues as you did...swapped the worm gear in my original actuator motor, swapped the whole actuator unit with a used one. during the motor swap I looked in the tcase and saw the gear teeth over rotated meaning tcase was done. Swapped with rebuilt and all is good.
Check this thread out:
https://www.e90post.com/forums/showthread.php?t=1431808

awesome. mine looks just like that. the actuator seems to have nothing to grab onto because that gear is rotated all the way to the passenger side. ive put about 5,000 miles on it like that. so best thing to do would be a new transfer case correct?

[BKV122]

Originally Posted by paulv824

awesome. mine looks just like that. the actuator seems to have nothing to grab onto because that gear is rotated all the way to the passenger side. ive put about 5,000 miles on it like that. so best thing to do would be a new transfer case correct?

Yes. New, used, or rebuilt are your options. I got a rebuilt one bc most local junkers had tcases at about the 100k+miles. I just didnt want to chance a used one were as mine crapped out at 145k, and started to show signs of issues around 100k miles

I put on about same amount of miles on mine till I finally got it taken care of.

[paulv824]

Originally Posted by BKV122

Yes. New, used, or rebuilt are your options. I got a rebuilt one bc most local junkers had tcases at about the 100k+miles. I just didnt want to chance a used one were as mine crapped out at 145k, and started to show signs of issues around 100k miles

I put on about same amount of miles on mine till I finally got it taken care of.

now if i do go with a used one, my car is a 6 speed mt. does it make a difference between an automatic or a manual?

[BKV122]

Originally Posted by paulv824

now if i do go with a used one, my car is a 6 speed mt. does it make a difference between an automatic or a manual?

Nope. I believe you can even use a 5 series TC. I used http://car-part.com/ looking at local used TCs. Enter in you car info and it will show compatible cars