[MartyMcFly88MPH]

Figured I'd share so we can keep track of how often this occurs.

Recently I noticed my 27k mile car being very rough under acceleration. It felt like it couldn't figure out how to put the power to each wheel. I shut off my tune (dinan stage 2), shut off traction control, tried different speeds, modes, shifting myself, etc... Nothing made it go away, so to the dealer it went, as I figured the T-case might be to blame.

The dealership determined it was the problem and replaced the part no questions asked under warranty, saving me $3900. Obviously this has me a little worried on such a low mileage car. I'm hoping its just a fluke and the new one holds strong. The SA said the new part has a new part # and should be a better revision.

I've launched the car twice and regularly go on a spirited cruise with a club in the mountains. However, I never really beat on it that hard. Its never been tracked under my ownership either. This has me worried about long term ownership and also has me hesitant to turn the tune back on, but I'm sure I'll get over it.

Side note: I had a 230 loaner. It was very Meh. Nothing about it felt special to me like the M235. Just my opinion, not trying to bash it.

[bryan_G01]

i beat my car everyday, 21.9 psi on the daily, hard shit, wind out to 6k, downshit leaving it hanging...

Never had a problem.

[wdc330i]

Was the car ever towed wheels down? Were any single tires replaced without replacing the others? Those are the only user error problems I can think of off the top of my head that could harm the transfer case.

[crabu2]

Originally Posted by MartyMcFly88MPH

Side note: I had a 230 loaner. It was very Meh. Nothing about it felt special to me like the M235. Just my opinion, not trying to bash it.

Haha.. I own a 230 and about half the time, that's exactly how I feel. It's really weird.. some days, it feels really quick, other days it feels like it can't get out of it's own way.. I might need a Vbox or the likes to see if it's just in my head.

BTW, how are your tires? If some of your tires are wearing quicker than others, it's going to cause a height change.. With AWD, you really want all your tires to be the same height or it can kill your t-case.

[fbsm]

Originally Posted by crabu2

Haha.. I own a 230 and about half the time, that's exactly how I feel. It's really weird.. some days, it feels really quick, other days it feels like it can't get out of it's own way.. I might need a Vbox or the likes to see if it's just in my head.

BTW, how are your tires? If some of your tires are wearing quicker than others, it's going to cause a height change.. With AWD, you really want all your tires to be the same height or it can kill your t-case.

I've been tempted several times to purchase an xdrive bimmer but it seems like they just cant build a durable/reliable AWD xfer case.......Subaru has been doing it for decades....and you can literally beat the piss out of the subaru......but somehow the german engineers cant nail this one......disturbing

[p912guy]

My m235i is a MT / RWD, so not a concern to me, but is this really a "common" issue? I don't recall reading or hearing much about this. Our local dealership is probably 4:1 xDrive over RWD of the cars on their lot, even though we generally see only 5-10 2-3" snowfalls on a heavy snow year. Is this also an issue in the X3 and X5 SUV's or are they using a different more beefy transfer case? We considered an X3 before we purchased our Q5. Audi seems to do FWD/AWD (Quattro) pretty well.

[fbsm]

Do a google search for bmw xdrive transfer case problems

There are a LOT of threads on bimmer forums about failures across many years and many models

[crabu2]

Originally Posted by fbsm

I've been tempted several times to purchase an xdrive bimmer but it seems like they just cant build a durable/reliable AWD xfer case.......Subaru has been doing it for decades....and you can literally beat the piss out of the subaru......but somehow the german engineers cant nail this one......disturbing

I never really looked at how BMW had their AWD setup, but on Subaru's they don't use a transfer case, they use differentials. Also, AFAIK, Subaru uses the same sized tire front and rear, but BMW ... it seems ... likes to use a staggered setup where the front and rear tires have different diameters. IMHO, unless the AWD system is very loose, having different front and rear tires are a no no.. It's going to wear out the t-case or diff because it's going to have to unload the tension from the front and rear axles spinning at different speeds.. even if it's very slight.

Personally, I don't feel BMW or any car company should be shipping cars with different F/R tires when it comes to AWD.

[fbsm]

Originally Posted by crabu2

I never really looked at how BMW had their AWD setup, but on Subaru's they don't use a transfer case, they use differentials. Also, AFAIK, Subaru uses the same sized tire front and rear, but BMW ... it seems ... likes to use a staggered setup where the front and rear tires have different diameters. IMHO, unless the AWD system is very loose, having different front and rear tires are a no no.. It's going to wear out the t-case or diff because it's going to have to unload the tension from the front and rear axles spinning at different speeds.. even if it's very slight.

Personally, I don't feel BMW or any car company should be shipping cars with different F/R tires when it comes to AWD.

Agreed wrt staggered tire sizes

But that really only explains the 2 series and similar

All of the X series and the rest of the more conventional vehicles all have square set ups which should eliminate the issue.

There are plenty of other examples of AWD out there.....Jeep has been using it for 40 years and its been reliable

A lot of the failures seem to be attributed to poor execution of the differential's construction......I would bet that the lack of required fluid service is a factor in failures above 50k.....lifetime fluid fill? My ass.....

[amw896]

I had an IS350 awd with a transfer case failing as well. Took them a long time of throwing random new parts in before calling in an engineer for proper diagnosis. Point is, I don't think BMW is notorious for transfer case and it's probably more of a one off. Lots of guys throwing loads more power down on their awd and having no issue. I feel for you though as I know it sucks ass getting a bad unit. At least yours is getting fixed quickly!

[Dylan86]

Seems like a rare occasion, to me.

[bimmerfile]

Originally Posted by fbsm

Do a google search for bmw xdrive transfer case problems

There are a LOT of threads on bimmer forums about failures across many years and many models

Actually, there aren't - and the ones which are generally are MYs prior 2012.

[wdc330i]

Originally Posted by bimmerfile

Actually, there aren't - and the ones which are generally are MYs prior 2012.

Agreed that transfer cases as a pervasive problem doesn't sound familiar. And I've had BMWs for 17 years, including 3 AWD versions. Certainly there are many more common problems through the fleet.

[xantdieselx]

How about the fact that the OP is stage 2? I know it's Dinan but you have to expect some additional wear outside of a normal range when running a tune. Yes our cars are over-engineered to a certain extent but really only BMW knows for sure how much tolerance is built in.

[MartyMcFly88MPH]

I'm assuming it was just a random failure as well. I only found one other thread about an M235 with this problem.

These cars should be able to take a beating. I drive mine spiritedly and even took it on an ice racing practice day, but even with that, I shouldn't be anywhere near the AWD limits.

The car has never been towed under my ownership. Tires are new this year and wearing evenly. I do have a staggered summer setup. If i remember correctly the front is 19x8.5 ET35 and the rear is 19x9.5 ET45.

[fbsm]

Originally Posted by xantdieselx

How about the fact that the OP is stage 2? I know it's Dinan but you have to expect some additional wear outside of a normal range when running a tune. Yes our cars are over-engineered to a certain extent but really only BMW knows for sure how much tolerance is built in.

Are they over engineered?

How many M cars considered major internal engine work to be regular maint at low mileage?

How about failing timing chains and tensioners......basic shit thats been around sincoe the dawn of the ICE

How about wheel bearing failures

This doesnt even take into consideration the thrust bearing failures on the B48 engines for almost every single one in Mini/BMW coupled to a MT for 2014-15

Fuel injector issues in the N54 engines

This is all stuff that is basic tech that BMW is failing on execution

I love the cars but too frequently the quality control seems to be lacking

[xantdieselx]

Originally Posted by fbsm

Are they over engineered?

How many M cars considered major internal engine work to be regular maint at low mileage?

How about failing timing chains and tensioners......basic shit thats been around sincoe the dawn of the ICE

How about wheel bearing failures

This doesnt even take into consideration the thrust bearing failures on the B48 engines for almost every single one in Mini/BMW coupled to a MT for 2014-15

Fuel injector issues in the N54 engines

This is all stuff that is basic tech that BMW is failing on execution

I love the cars but too frequently the quality control seems to be lacking

Compared to other cars out there yes they are absolutely over-engineered.

I've owned 4 BMW's out of about 15 or so new cars in my life. Hands down they've been more reliable than every other make (including Honda, Subaru, Infiniti, Mitsubishi and Hyundai just to name few). So in my experience yes they absolutely are.

[Luddy]

Yeah I think (knock on wood) this isn't a common problem. Yes, you can search bmw transfer case issues on google and find some but many of them are from the 2011-2013 range and also the ratio of xdrive cars sold in northern regions to issues posted seems to be in favor of this not being widespread.

I personally have found BMW's pretty reliable
1988 528e - Brake master cylinder went bad, heater box rusted out. This was a 14 year old car when I got it though.
1996 328i - no major issues
1999 528i - no major issues besides the drivers side vapor seals failing repeatedly. The worse one requiring the seats to be removed to remove the carpet so it could dry. They covered that at no cost since there initial fix of the vapor seal did not work.
2007 328xi - Water pump failure at 107k (I actually didn't know about this issue till I was stranded)
2016 M235i xdrive - FEM (Front electronics module) failed at 1k miles requiring tow to dealer

At least based on my experience I wouldn't worry about the transfer case once it is fixed. For the number of xdrive cars sold it doesn't seem to be mentioned on many forums.

[lieb923]

Just replaced mine under warranty. 10k. It had multiple driveline shudders under 10mph.

[casualDIYer]

I've never been convinced that AWD was a feature any city car would ever need. The car companies made RWD forever then it was FWD, the technology meant to supplant everything else but was really designed to save on cost. Then we got SUV mania followed by the AWD craze. So, I get this BS 'dog and pony' show about how advanced AWD is at the showroom while BMW's most advanced electrics are all .... RWD. So what's the story? The auto industry is trying to get you to part with your hard earned money by feeding you all kinds of outlandish nonsense. But why wouldn't they? It's the 20-teens -- era of the luxury pickup truck.

In my opinion the diff based AWD systems are superior in terms of their reliability and ability to slam a majority of power into a single wheel. Electronic systems meant as a cheap way to avoid putting in expensive diffs, seem great on fuel economy but are much more prone to problems, or so it seeems. XDrive seems better at its axle based approach than some competitors but it's still no replacement for a diff.

As for the Germans on AWD, which Germans? The Cayanne would likely kick the ass of most AWD competitors. Then again, most anything going up against Porche often gets an ass kicking.

[MartyMcFly88MPH]

Originally Posted by lieb923

Just replaced mine under warranty. 10k. It had multiple driveline shudders under 10mph.

Sorry to hear. Mine just got a CEL now too. To the dealer I go this morning. Its all a bit unnerving.

[MartyMcFly88MPH]

Originally Posted by menncars

I've never been convinced that AWD was a feature any city car would ever need. The car companies made RWD forever then it was FWD, the technology meant to supplant everything else but was really designed to save on cost. Then we got SUV mania followed by the AWD craze. So, I get this BS 'dog and pony' show about how advanced AWD is at the showroom while BMW's most advanced electrics are all .... RWD. So what's the story? The auto industry is trying to get you to part with your hard earned money by feeding you all kinds of outlandish nonsense. But why wouldn't they? It's the 20-teens -- era of the luxury pickup truck.

In my opinion the diff based AWD systems are superior in terms of their reliability and ability to slam a majority of power into a single wheel. Electronic systems meant as a cheap way to avoid putting in expensive diffs, seem great on fuel economy but are much more prone to problems, or so it seeems. XDrive seems better at its axle based approach than some competitors but it's still no replacement for a diff.

As for the Germans on AWD, which Germans? The Cayanne would likely kick the ass of most AWD competitors. Then again, most anything going up against Porche often gets an ass kicking.

City car?

This is my ski car, road trip car, and canyon cruising car. I regualary take it 700 miles round trip to Utah. I just got back from Aspen. I'm heading to Banff with it in Sept for a camping trip. It is incredible at all of these tasks as long as the damn thing can stay reliable.