X5 is fixed, one last hurdle.

[jhall]

I'm not sure if anyone will remember my x5 problems, but I finally have it all back together and functioning. To recap: first the timing guides went, turning the m60 into scrap, then after I refreshed a used m60 and dropped it into place, the front driveshaft pulled out and punched a hole in the transmission. So we patched it up, aqnd I rebuilt the transfer case.

Now she starts, runs, and stops like you would expect a car to do.

However I have a slight trans fluid leak. A picture is worth a thousand words so here you can see the repaired assemble area and the damage after the impact.



The leak seems to be happening around the top of the "inside" washer pictured. Clearly there's a little bit of a bump-out from the weld. Everything now is torqued to spec but it still has a slow seep around that washer.

And here is the damage before the repair.



I'm looking for ideas on what to do, I know grinding it down should help. And I've been suggested maybe some nylon washers to fill the gap. I'm still trying to be gentle with the area and not destroy or re crack anything. Any suggestions are greatly appreciated.

[ldsbeaker]

Yes, I remember. You've been busy, eh?

I guess filing it down by hand would be the most gentle way.

Good luck!

[jhall]

Yes, I remember. You've been busy, eh?

I guess filing it down by hand would be the most gentle way.

Good luck!

Ha, yeah, a 2 year old, travelling for work, work, slowly updating a house, 20 year old BMWs, and a perpetually broken x5. I'm sure you all know the feeling.

[ahab]

Second the careful filing. Depending on the working space it shouldn't be too tough, the banjo fitting looks slightly canted in the photo.

Edit, does the washer have the rubber liner in there? I would assume yours is aluminum too but it doesn't look that way in the photo. Our E28s use those at the PS pump.

[jhall]

Second the careful filing. Depending on the working space it shouldn't be too tough, the banjo fitting looks slightly canted in the photo.

Edit, does the washer have the rubber liner in there? I would assume yours is aluminum too but it doesn't look that way in the photo. Our E28s use those at the PS pump.

Yes, I made a mistake the first time, I used a standard crush washer thinking I'll pull a fast one on BMW and not buy the $8 washers.... it leaked like a sieve. So I bought the correct parts and quickly realized my mistake.

That's 2 for filing it down, the area is a little tough to get into because of the driveshaft, but I can probably make it work.

[ldsbeaker]

Hand files are cheap at harbor freight, break to fit.

[Mike W.]

X3 for filing it down. I think I see a gap up at the top. Being the cheapskate I am, I think about things like an extra crush washer and giving it a couple of wraps in teflon tape.

[jhall]

Didn't think to use teflon tape, pondered maybe a silicone to take up the gap, but I don't want to keep compounding my dumb decisions with other dumb decisions. Knowing my luck a chunk of silicone would break off and plug some line somewhere and burn up thre trans.

[demetk]

What kind of weld is that? It's not JB is it?

[jhall]

What kind of weld is that? It's not JB is it?

The repair was tig welded, and quite well if I say so. My FIL did the repair and he got it to where the hollow bolt even started into the threads. Then I tapped it out the rest of the way. Then I did a coat of JB over the top of everything just to cover any pin holes. I'm terrified it will crack again, but for now I just have to go with it.

[Kyle in NO]

Before doing anything, I would try stacking 2 of those $8 washers on the inside to gain more flex, possibly sealing the leak easily.

[davintosh]

Wow; kudos for sticking with this project and getting it back on the road! Very impressive, considering all that's happened. Ready to sell it now?

I've never dealt with stuff like that before, so no original suggestions from me, but I hate doing stuff over again, so I'd probably go for a combination of filing and Kyle's extra washer. And adding the Teflon tape might make for a magic trifecta. Just get that puppy stopped up and drive it!

[jhall]

And the winner is ...double washer with a bit of teflon tape. I tried to get a file in there but mine didn't fit. For now it seems good. I owe you guys a beer or eight if I ever make it to a get-together.

As for selling it, I feel married to this thing now. I've had pressure from a lot of family and friends to sell it once fixed, but given the work I've had to do I feel sheepish, like I'd be selling someone else a headache.