The dreaded Angle Gear- some advise please!

[cn90]

If you want great AWD system at low cost: look for a 2004-2006 BMW E53 X5 with low mileage.
My 2006 X5 3.0i with 140K miles is running fine.

The BMW AWD system is fantastic, none of this angle gear issue...

[volvooh]

I am in a quandary about this. Nothing I know is guaranteed, but assuming it is the sleeve or sleeve and angle gear and are replaced with a sleeve kit and quality angle gear, should I expect to get another 50k miles out of it?

[ggleavitt]

The unknown is the welded sleeve repair mentioned earlier. If the angle gear/sleeve weld is still holding and you're stripped, problem is maybe now on the transmission side splines and that is not something that I see can be fixed in place anywhere sort of reasonable.

Nevertheless- assuming that the issue is just a stripped out angle gear input shaft and/or the sleeve, a decently splined angle gear with a new sleeve and seals will put you back to right. For how long, maybe as long as it took to strip the original which I'll guess is more than 50k miles.

[volvooh]

Thank you. I hoping that either OP didn't do a good welding job or lied about doing it in the first place. I did at one time see a receipt in my car at one point for a pull off angle gear, so I can say that was most likely replaced. I agree, if the transmission side splines are stripped I am likely out of luck. Unfortunately, if that is the case I am still out $350 for the R&R of the angle gear.

[Blacklab467]

It is a pretty easy job to pull your angle gear off and see whats going on in there. You will not need any exhaust gaskets either. I've attached a link to the job I did on my car ( 2003 XC 70) which shows how to get everything apart and out of the way. You can even reinstall the right CV shaft and drive the vehicle without the angle gear while you source a new one.
It's well worthwhile to fix your AWD, you can probably also count on having to replace the Haldex pump, these are a high fail item and should be changed when you have the propshaft off. Buy the Volvo pump, DO NOT BUY AN AFTERMARKET BRAND PUMP!!! It's also good that you have no DEM codes.
viewtopic.php?f=9&t=95073