Gearbox problems - complete loss of drive

[Steve Blackdog]

Hi Folks

After 112k of faithful service my E53 3.0D Sport had to be come home on the back of a tow truck this evening.

SWIMBO told me that the Auto Trans Fail Safe warning came up.  We had noticed the engine sort of catching at around 40mph, but otherwise appeared to be rock solid.

I took the car down to my Indie BMW garage this afternoon.  They put it on the computer and identified problems in the gearbox.  He said maybe try a gearbox oil service, but if that doesn't help you will need to see his recommended gear box specialist.  So I drove 1 mile to centre of Warwick for a coffee.  By the time I got there the engine had started over revving. 

When I got back to the car, the gearbox would hardly engage, but gradually pulled away - revving very high.  I got a couple of miles on the way home and it got worse and worse and eventually all drive was lost.

So I have no drive whatsoever in all forward and reverse gears.  The engine revs as if it is in neutral.

From reading other posts, I'm wondering if the torque converter has gone and maybe some other nasty stuff as well.  I'm bracing myself for a big bill - I'll need the car to be towed to the garage for a start off.

What do you think?

Cheers

Steve

[Greydog]

Ouch!! Sounds like you need a good Auto Box specialist, sadly whatever the problem it doesn't sound a quick fix.
I had a problem with one of my Mercs (all drive lost) which turned out to be electrical, a loom problem. It was still flipin expensive.
Hope it's a simple fix

[X5Sport]

Oh dear.

Whatever you do, don't drive it any further.  If the TC has lost pressure then that will most likely also affect the clutch packs and if that has happened you are looking at a complete rebuild.

Mine was a TC failure and it took out the oil pump, 2 clutches and one brake set, and later they identified a damaged Mechatronics unit.

For a gearbox rebuild then the cost will be around £1,800 to £2,500.  BMW will want about £7k.  If the Mech unit has been affected then add another £1,500 or so.  It needs to be replaced with a remanufactured/new unit.

Don't know where in the country you are, but there's a ZF specialist in Bedfordshire who the major warranty companies use.

Sorry........

Richard

[Steamyrotter]

Richard
According to his sig its a pre facelift 2003..
Therefore GM 5L40E

First thing to do is to get the fluid pressure checked. (you will need a 0-16bar (240psi) guage on a M10 fine adaptor)
On tickover should be approx 50-60psi
Running in gear could be anything up to 230psi.
You can check actutator current on diagnostic port (wiht right scanner) and compare with details in the manual (See another of my post to the link to the 5L40E rebuild manual - http://xdrivers.co.uk/forum/https://xdr ... 0#msg22270)


Simple check is to get it warm - tick over should be 50-60, put in reverse and you should get min 120psi (or thereabouts)
If not then you will have wear in the pump and the bellhousing will need a major overhaul...

There are issues with the torque convertor linings coming off.  Whether this is cause or effect of loss of pressure is anyones guess.  But loss of pressure will cause the TC lock up clutch to slip.

The valve bodies are susceptible to wear as they are hardened valves in snotty aluminium housing.  OK when everything is clean, but get any dirt in there and it will score the bores and cause fluid passing and pressure drops..  You can get these sorted at approx £150 - £300 depending upon amount of valves replaced.

Clutch packs can be changed and are available, and brand new torque convertors are still available surprisingly...


The other side of the coin is it could be a battery / alternator issue causing it????
Get a proper diagnostic done by someone who knows and do not settle for the first quote / comments unless you thoroughly trust them..

I can go on for hours about my trials & tribulations in sorting my box out, and i have got a folder approx 3" thick with documents i have researched during my gearbox woes...

[X5Sport]

Missed the pre-facelift.... :doh:

Hopefully the 'worst case' scenario will not be the one that is found to be the actual problem.  Most of the costs on my repair were the labour getting the box out, rebuilding and re-installing.  I think the spares for a major rebuild were around £700 inc VAT.

Richard

[Smeeagain]

Vague recollection from posts a couple of years ago that Jason, he of chiptune fame, does gearbox rebuilds? Or did I make that up?

[Sanj]

[quote="Smeeagain"]
Vague recollection from posts a couple of years ago that Jason, he of chiptune fame, does gearbox rebuilds? Or did I make that up?
[/quote]

Made it up, but yes try him.

[Steamyrotter]

[quote="X5Sport"]
Most of the costs on my repair were the labour getting the box out
[/quote]

Only takes 1.5 hours...



After you have practised it a few times..........

:-[ :-[ :-[

[X5Sport]

Yes indeed.  And you've had rather too much practice..... :rant:

I think the overall was 17.5 hours to do the lot....and once was enough!

R

[Steve Blackdog]

I'm going to drop the sump and see how much crud there is.  I might just replace the filter and fluid and limp on for a bit, but if it looks like I can write my name in the gunk, I guess I might as well bite the bullet and get the box rebuilt.

I'll keep you posted.

SWIMBO is looking around for new cars.

[Steve Blackdog]

Here's the promised update.

I changed the Automatic Transmission Fluid and put in a new filter.  The problem is deferred rather than solved.  The car now runs as it should.  ECU probably confused as it lurches a little on pulling off.  But one running everything runs well.

I did pay a visit to Ken at Transmission Technology in Knowle, who is a 100% gent.  He advised me that if you can write your name in the sludge in the sump, the gearbox needs a recon.  There was so much sludge in my sump that I could write the complete works of Shakespeare and still have enough to start on War and Peace.

I'm not going to spend any more on it. I have had my money's worth ten times over. We have just agreed a part-ex on it for a nearly new E70!  Hopefully that will do me another ten years.

But for the record, the transmission service does solve the problem of loss of drive.  The loss of drive was caused by the blocked filter.  If the torque converter and/or box is full of crud, it is only a matter of time until the filters block up again.  Could be 500 miles, could be 50,000.  If I was keeping it I would budget to recon the box in the next 12 month. NB this might not be the case if I had the ZF box, which is easier to sort than the GM and also more resilient.

[Smeeagain]

[quote="Sanj"]
[quote="Smeeagain"]
Vague recollection from posts a couple of years ago that Jason, he of chiptune fame, does gearbox rebuilds? Or did I make that up?
[/quote]

Made it up, but yes try him.
[/quote]

Turns out I didn't make it up. I asked him and yes they do do it, in house, £1600 (£1650 if it needs a solenoid), converter included.

Smee