NHTSA Complaint #10604531 — 2003 BMW X5

STOPPED AT RED LIGHT AND WHEN RESUMED DRIVING AT GREEN LIGHT, SUDDENLY HEARD LOUD GRINDING NOISE IN DRIVE MODE (D). STOPPED CAR IMMEDIATELY. TUNED OFF ENGINE AND STARTED AGAIN AFTER FEW MINUTES AND SAME GRINDING NOISE IN DRIVE MODE AS WELL AS REVERSE MODE. NOT ABLE TO MOVE THE CAR WHEN ACCELERATE. TOWED THE CAR TO MY LOCAL BMW MECHANIC (HE HAS HIS OWN SERVICE CENTER NOT A DEALER OWNED). DURING PHONE CONVERSATION, HE SUSPECTED ITS SOMETHING TO DO WITH TRANSFERCASE/FRONT DRIVE SHAFT AND UPON PHYSICAL INSPECTION HE CONFIRMED ITS THOSE TWO PARTS. THE SPLINE CONNECTION BETWEEN DRIVE SHAFT AND TRANSFER CASE WENT BAD. THE MECHANIC KNEW OF THIS ISSUE HAPPENING IN SEVERAL X5S BUT NOT AT SUCH LOW MILEAGE (51K ONLY). ENDED UP REPLACING THE BAD PARTS THROUGH HIM AS I HAD NO HOPES DEALER WILL FIX THIS ISSUE AT THEIR EXPENSE BASED ON SEVERAL READINGS ONLINE AND FEEDBACK FROM OTHER CAR OWNERS. TOTAL REPAIR COST $4000 OEM PARTS PLUS LABOR. READ IN SEVERAL BMW FORUMS (BIMMERFORUM, BIMMERFEST ETC,) THIS IS VERY COMMON PROBLEM. EXPERTS BELIEVE IT IS DUE TO A DESIGN FLAW IN THE CONNECTION BETWEEN FRONT DRIVE SHAFT AND TRANSFER CASE (DRIVE SHAFT BEING AN INCH SHORT).THERE ARE CUSTOM FRONT DRIVE SHAFT AVAILABLE THAT ARE ABOUT 1INCH LONGER THAN THE OEM PART. ANOTHER FACTOR THAT MAY BE DRIVING THIS ISSUE COULD BE RELATED TO AC CONDENSATE PIPE LOCATION RIGHT ABOVE WHERE THE DRIVE SHAFT AND TRANSFER CASE CONNECTS. I READ THIS IN ANOTHER COMPLAIN BUT UNABLE TO CONFIRM AS I'M NOT THE MECHANIC. BASED ON THE SAME ISSUE REPORTED SO FAR (AND MANY THAT ARE NOT REPORTED JUST BECAUSE NOT EVERYONE IS INTERNET SAVVY TO REPORT), IT IS HIGH TIME BMW NEEDS TO BE PUSHED FOR REPAIRING THIS ISSUE IN FUTURE AND REFUND REPAIR COST FOR THOSE WHO ALREADY FIXED IT ON THEIR OWN. *TR