Sarge

Hi,

My 2008 535xi wagon (110k miles) is showing the '4x4 Malfunction, drive moderately' error. It happens on startup, after two brief periods of a 'k-k-k-k-k-k-k-k' (two second pause) 'k-k-k-k-k-k-k-k-k' noise - and then the error message comes up.

From what I've read, this is probably the transfer case plastic actuator gear failure that seems to be fairly common on X3 and X5 vehicles of the last five or more years, usually at higher mileage.

In the first-gen X3, some people have taken the actuator gearbox apart and simply flipped the gear around, because it only uses half the gear - and that's the free fix.

I'd like to just order a new gear, but I haven't seen anything confirming a similar solution for the E60 AWD vehicles. Do they use the same exact actuator gear? Anyone have any experience with this?

Thanks in advance.

Sarge

Just bumping this up again. I've not found any answers after months with this problem.

Is the Xdrive/xi transfer case actuator gear the same in the E60 as in the other E90, E83, etc xdrive vehicles? Anyone know?