E60 All Wheel Drive Mechatronics sleeve replacement
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Join Date: Mar 2011
Location: Temecula, CA
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My Ride: 535xi
Model Year: 2008
Engine: N54
To remove the rear transfer case mount:
1. Remove 4 nuts (10 mm) where exhaust pipes meet downpipes.
2. Remove heat shield bolts (various 8 mm and 10 mm bolt/nuts) - just let it rest on top of the exhaust pipes - you're just trying to make room to remove the transfer case bolts
3. remove 6 transfer case/tranny mount bolts (13 mm I believe)
At this point, the bracket for the transfer case/rear of transmission is low enough that you can reach above it to slide the new sleeve into it's position.
Hope this helps someone out there dealing with the same situation on these unique AWD 5 series cars. I just did this job a few weeks ago on a 335i and it was a breeze, because it was RWD. The AWD components add complexity and create tight packaging.
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808E61 (08-26-2021)
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