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Are you guys doing this conversion on xdrive cars or on pre-2003 awd models from BMW? As from how I understand it on the E53 X5s, BMW used a more mechanical awd system up until 2003. I've seen a lot of post-2004/facelift guys doing the RWD conversions, but that's going to be a given, since there are many more examples of those out there.
 

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I have been playing around with this for several months in my spare time.
The ring gear assembly can be easily removed- pull the output flange (3-arm puller), than the seal, and lastly a snap ring and put that half of the TC on a shop press and it came right out.

Unfortunately I found this out much too late. While I was welding the gears it must have gotten too hot or too much spatter because it would not turn smoothly anymore.
 

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I’m looking for a transfer case for a 2005 330xi. Anybody in norther California, or willing to ship to 95666?


Sent from my iPhone using E46Fanatics
 

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Here we go...round 2. I snagged another TC and have it apart on the bench.

Ive been thinking....why not pull the gear off in red if it has no use once the ring & planets are welded? Its held in with the same "constant section" ring as the ring gear is.

Also...isn't it still putting 60% of the power to the front drive even though theres nothing technically being driven w/ no front drive shaft?
 

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Trying something a little different.
This has a root and cap at each of the 3 sections.
The ring & carrier are hardened so it had to get pretty hot to get good penetration.



 

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I am thinking about trying this on my 330xi Touring.

I already have a spare TC lying around and I can't get red of the clunk in my drivetrain. (I suspect the TC as being responsible for the clunking as almost everything else is changed on the drivetrain and suspension).

Before I try this Mod I would appreciate if the ones that have already done this could post their long term experiences.
I am particually interested in the behavior of the DSC system after this mod, does it cause complications when the front drive shaft is disconnected during normal and/or "hard" driving ?
 

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Yes....even if I lean in hard on a highway on/off ramp with DSC on it will flash & interfere.
Other than that, no DSC issues.
Turn it off and it does not interfere.
 

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I did it!

I did it! :evil:

I converted my 330xi to RWD 2 days ago by welding the planetary gears inside of the transfer case as described in this awesome Thread!

The TC opens pretty easily by removing all the surrounding bolts, I did not try to remove the bearing to the rear-output shaft because I was pretty sure that by doing that I will destroy this bearing. So it got welded inside of the TC, I did my best to cover the holes and other bearings with aluminiumfoil so no welding-splatters could get in there. Nevertheless after welding I had to clean out the TC thoroughly and still found quite some splatters in there, hoping I got everything out before sealing and putting together the TC and refill it with oil again.

After 2 days of driving I can say that I am pretty happy with the result of this mod. The awefull drivetrain-clunk which I have been trying to get rid of the last 2 years is finally gone, From this I conclude that the play in the transfercase, especially the play in the planetary gearwheels add up with the play in the others gears and bearings of the TC and were the cause of this problem.

Wonder how much play these NV-124 transfercases had when they were new from the factory.

I as well changed the clutch and the dual-mass-flywheel on my car which was a pretty P.I.T.A.-job because I had to remove the gearbox but thats a diffenent story.

Only the results count and the result of this RWD-conversion together with the new clutch and flywheel is that my car drives like a BMW should drive again, awesome, very happy with it. I never wanted a AWD e46 anyways...

DSC:
During normal or even "sporty" driving there are no issues with the DSC kicking-in so far, only when
accelerating out of tight curves the DSC smoothly intervenes, this can be turned of by manually pressing the DSC button.

Is there is a known possibility to get the DSC working like a RWD car ?


Special thanks to Manchicle (is he still around here ? ) who came up with this idea and all the others who contributed here. :bow:
 

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I want a locking center diff. Open for 92% of the time, push the button, lock the center for when there's real snow down.

BMW's computers just don't know how to drive in sloppy, goopy, deeper snow where wheelspin is a tool, not a problem.

But then, I would also want a mechanical LSD, because having the computer pull the throttle to prevent wheelspin is just not cool.

t
has welded diffs before. Wouldn't do it on the street.
 

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I don't own an xi, but damn I wish I could seasonally switch between awd and rwd. Nice job. For $200, sounds like a pretty good deal, even if some labour is involved. Next project, find a way to switch it on the fly. <img src="http://s1.E46Fanatics.com/forum/images/smilies/wink.gif" border="0" alt="" title="Wink" class="inlineimg" />
This is what I***8217;m talking about. I mess with both the response from this guy, and I also like how innovative you are because it***8217;s something I***8217;ve pondered on and wondered what it would require me doing. It***8217;s essentially like welding the diff, (which I***8217;m wondering btw, did you end up doing that while you were at it?) which isn***8217;t an uncommon practice. The only thing is you***8217;re brave for removing the drive shaft, but I guess if you did it with no problems, it is what it is!

Idk what that other guys problem was, he was treating you like you committed a sin loool. I will definitely look into this more. If you can still give tips that aren***8217;t in this thread please do!
 

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Hello.
Can the front axles be removed, after welding the TC ?
No. The Axles have the ABS tone rings. Well, I mean, you could but traction control would go insane every time you drove the car. The wheels probably woudn't fall off but you may compromise the structural integrity with no axels in there.

I suppose you could replace the spindles with RWD ones but I don't think they'd line up correctly.
 

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Hello.

Can the front axles be removed, after welding the TC ?

After almost 1 Year of driving with the "$200 RWD-Conversion", I noticed that while maneuvering at low speeds and max. steering angle engaged, my wheels on the front axle started to jerk noticable.

Reason for this behavior was the front-differential, with the disconnected front drive-shaft but the front-axles still connected to the front-diff.

You cannot just remove the front-axles because the outer-connection of the axle is needed to connect to the wheel-hub and wheel-bearing. The inner-side-connection of the front-axles are connected to the front-diff, sealing it from oil coming out and dirt comming in.

So the idea was cut-out the middle-element of the front-axles and re-connect both ends to the wheel-hub and front-diff again.
Notice that you will destroy your front-axles by doing this!

Well, on the pics you can see how that looks like.
I'm driving like this for about 2 Months now and I am very happy with it, it works.
The frontwheels turn 100 % independently now, like a "real" RWD car.
 

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