So at 16000 miles I notice my tcase was leaking...based on what other people have said,I presume it was the overfill issue so I pulled the fill plug and fluid started coming out...not toooo much but alot had previously been leaking from probably the vent tube. So my estimation is that it was atleast .5 liters total overfilled. I also have a very convenient whine now..very faint and at certain speeds, but my presumption is from the tcase. Also, attached is a picture of the drain plug from the tcase. Now Ive worked on BMW's for 5 years and my best guess is this is not an acceptable level of metal. I REALLY REALLY dont want to take it to the dealer, especially since A. Ive been a tech and know what goes on at the dealer... 2. I leave for the Marine Corps in 6 weeks and rather enjoy my car while I can instead it sit at the dealer.

So basically I refilled with some Lucas synthetic oil, changed the rear diff fluid too, and buttoned her back up. Noise is still there, but its not horrible. I suppose at this point Im just prolonging the inevitable. If it does go out any time soon, hopefully warranty will cover, if not it will be sent to sheppard or something

I also am not 100% of the source of leak. I am assuming at this point it was due to overfill. I have not put enough miles yet to confirm. Hopefully no further external/internal leaks to revive this problem as I can deal with a intermittent slight whine, but not leaking fluids.

 

when i changed my oil for the first time on my tcase i had that much shavings on my drain plug.
Now if this issue come about over and over for you then i would call it suspect

 

Mitsu transfer cases and rear diff's are very particular about the fluid in them. I wouldn't have used anything other than the oem diaqueen lsd gear oil in the rear diff or transfer case. Even shep will tell you the same, although sometimes he uses redline heavy shockproof in the transfer case. I would change them back to oem asap.

 

Really? I'm not the only one that had this much metal? Wow..



And it's a synthetic hypoid 75w90 gear oil. I'm not all that worried about it

 

So that much metal is considered normal?

 

wow, Im surprised no one else has any input?

 

Mine had about that much shavings as well at 15k miles. Are you sure the whine you hear hasn't been there the whole time? These drive trains are noisy as hell. Also, the general consensus is to use OEM fluids in the T-case and diff. That is your call though.

 

If your transfer case was really leaking, you would see the remnants of it all over you downpipe, cat, and surrounding areas. It is quite noticeable and messy.

 

^ and smelly

 

It was, perhaps I left that part out.. But Im under the assumption that it was leaking due to overfill hence the part where I stated I removed the drain plug etc....as of now, everything was cleaned up and no further leaks, but still a noticeable whine at certain speeds.

 

I had the same exact problem at 16,000. At 22,000, it started whining and grinding to the point that you cannot even hear your own music. I had it warrantied.

EDIT: Mine also had leaks and large quantities of shavings.

 

what kind of noises did it start making at 16k? Mine are extremely faint, but noticeable...Ill prolly wait till after boot camp to take it to dealer so I can enjoy my car now