2023-2024 BMW X1, X2 Double Clutch Transmission Rework

What's the Problem?

BMW has identified that micro-movements, combined with frictional corrosion, can lead to increased wear on the longitudinal splined connection. This connection is located between the double clutch transmission (DCT) and the transfer box in certain vehicles. This wear can potentially affect the long-term durability and performance of the drivetrain components. The correction involves adding spacers at this connection to decrease these micro-movements.

Important Owner Information

BMW advises that this procedure should be performed on all affected vehicles before customer delivery. If a customer has already taken delivery, the procedure should be completed the next time the vehicle is in the shop, provided the campaign status is remedy available. Otherwise, the vehicle can be released.

Repair Procedure Summary

The repair for the BMW X1 double clutch transmission issue involves several steps to install spacers at the connection between the double clutch transmission and the transfer box. Technicians should follow Repair Instruction 31 60 004 titled "Removing and installing/replacing right output shaft." To access certain bolts for the spacer, the starter motor needs to be removed or moved aside.

As part of the procedure, the stabilizer link (labeled as '1' in the provided diagram) must be removed. Upon reinstallation, bolts '2' and '3' should be replaced and tightened to 100 Nm and then torqued an additional 90 degrees. Subsequently, two bolts (labeled as '1' in a second diagram) on the transfer case are removed. These bolts must also be replaced upon reinstallation and tightened to 100 Nm with an additional 90-degree torque angle.

Washers are then installed between the link and the transfer case. It may be necessary to slightly push the transfer case to the side to facilitate washer installation. Finally, the right axle is reinstalled.

If Repair Instruction 31 60 004 is not available in AIR/ISTA, technicians can use Repair Instruction 27 10 110 titled "Replace radial shaft sealing ring for connecting shaft right" as an alternative. However, it is important to note that, contrary to instruction 27 10 110, it is not necessary to replace the shaft sealing ring with part number 27 10 8627023 for this specific service action.

Required Parts and Materials

To determine the correct part numbers for a specific vehicle, the VIN/chassis number should be entered into ETK or AIR. The following parts are listed for this repair:

• 07 11 9 909 844: Hex Bolt (M12x1.5x90) (Quantity: 1)
• 07 14 9 894 132: Multi-purpose bolt ASA (M12x90x1.5) (Quantity: 2)
• 27 10 0 907 707: Retaining ring (Quantity: 1)
• 37 14 6 869 771: Thread-tapping hexagon bolt (Quantity: 1)
• 31 20 6 866 022: Shouldered bolt with compression spring (Quantity: 1)
• 22 11 8 876 816: Adapter washer kit (Quantity: 2)
• 33 30 6 760 587: Flanged hexagon nut (Quantity: 1)
• 31 10 6 876 027: ASA bolt (Quantity: 1)
• 07 11 9 909 527: Hexagon bolt (Quantity: 1)
• 07 11 9 906 927: Hexagon bolt (Quantity: 1)

Additionally, other materials and small parts, such as fluids, lubricants, one-time use screws, nuts, and seals, must be selected from the Electronic Parts Catalog (ETK) or other approved BMW resources according to the vehicle type. These items should be invoiced separately under the Repair Code listed in this bulletin.

Claim Information

Reimbursement for this Service Action is processed via normal claim entry. The Repair Code for this action is 0028240100, described as "U10 U11 Reworking DKG connection - transfer box."

There are two special flat rate labor operation codes for this action:

• Work Package #1: Labor Operation 00 75 871 for "Reworking the interface between the double clutch transmission and the transfer box." This is used when the repair is completed before the first vehicle delivery or if the vehicle is already in the workshop.
• Work Package #2: Labor Operation 00 75 284 for "Reworking the interface between the double clutch transmission and the transfer box." This is used when the vehicle arrives at the service center with this Service Action open and no other main work is performed.

Only one of these flat rate labor operation codes can be used for claim submission. For bulk supply materials, Sublet Code 4 allows reimbursement up to $25.00, but BMW part numbers should not be used for claim submission under this code. Alternative Mobility Solution (AMS) expenses qualify for reimbursement under Sublet Code 2; refer to SI B01 29 16 for additional information.

Feedback Regarding This Bulletin

BMW encourages technicians to provide feedback on this bulletin. Technical feedback can be submitted via the rating box at the top of the bulletin. Warranty feedback should be submitted through an IDS ticket to the Warranty Department or via the chat in the Warranty Documentation Portal. Parts feedback should be submitted through an IDS ticket to the Parts Department.

NHTSA ID: 10255557