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  #21  
Old 03-24-2017, 11:05 AM
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Update: For convenience and speed, I ordered the used valve body with warranty/guaranteed working EGS and paid $450 including shipping. With my valve body working perfectly, we are going to just swap out the EGS today and test it out.
With all the feedback received from this forum, testing from the mechanic, and information shared from the repair company in Bulgaria, the EGS hardware/circuit board has failed and needs replaced. Hopefully, the used EGS does not fail anytime soon as the repair company in Bulgaria said all EGSs will fail at sometime. I will have the old one as a spare and I am currently research the best place to send it out to for rebuild. I would rather have a rebuilt EGS waiting for the next transmission service and will swap the rebuilt EGS out in the future. Plus, I will have used working valve body waiting in case the current unit fails in the future. If anyone needs either the broken EGS or the used working valve body, let me know. I would consider selling both or individually to help someone else out as both these parts are scarce to find used as cores. Might help someone else get back running faster instead of dissembling their transmission and sending parts out for rebuild.
I will post the results as soon as I confirm the EGS swap/repair solved my problem.
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  #22  
Old 04-03-2017, 09:55 AM
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EGS swap completed. 500 miles on the repair and everything is perfect. Transmission is operating way better than ever before. Probably results of new fluids and software update. $850.00 Total cost for used Mechatronic with working EGS, swap out of EGS onto existing valve body and labor to complete repair. Now I have a used valve body with a bad EGS for sale if anyone is in need. I will hang onto the parts for a while in case I have another EGS fault. But, I am also considering sending the EGS out for repair and then selling the full Mechatronic unit as a repaired/working used unit. Just need to let the pocket book recover for few weeks before dropping another $375 into the EGS repair. My goal would be to sell the working used Mechatronic with repaired EGS for $1200 or best offer. Trying to recover as much of the repair as I can. Might be a lofty goal on the price but that is about half the price of new Mechatronic unit with a EGS.
Thank you to all those who responded to this post and gave suggestions. Hopefully, this post will help others find the solution faster than I did. In total, we spent about 2 months chasing this repair down with trial and error. Might have had several issues all at the same time but most likely, we replaced parts that were not needed as the EGS on the valve body was the problem.
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  #23  
Old 04-06-2017, 11:01 PM
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Quote:
Originally Posted by jb4realestate View Post
EGS swap completed. 500 miles on the repair and everything is perfect. Transmission is operating way better than ever before. Probably results of new fluids and software update. $850.00 Total cost for used Mechatronic with working EGS, swap out of EGS onto existing valve body and labor to complete repair. Now I have a used valve body with a bad EGS for sale if anyone is in need. I will hang onto the parts for a while in case I have another EGS fault. But, I am also considering sending the EGS out for repair and then selling the full Mechatronic unit as a repaired/working used unit. Just need to let the pocket book recover for few weeks before dropping another $375 into the EGS repair. My goal would be to sell the working used Mechatronic with repaired EGS for $1200 or best offer. Trying to recover as much of the repair as I can. Might be a lofty goal on the price but that is about half the price of new Mechatronic unit with a EGS.
Thank you to all those who responded to this post and gave suggestions. Hopefully, this post will help others find the solution faster than I did. In total, we spent about 2 months chasing this repair down with trial and error. Might have had several issues all at the same time but most likely, we replaced parts that were not needed as the EGS on the valve body was the problem.

Good day!!

I have swapped out the EGS in my trans for one from a 2006... I got the ICOM and laptop to program it and the transmission computer... I must be running on old software as I am getting the hard 1-2 shift, the 3-4 flare, and slow engage into Rev and Drive... So, the only thing I need to have done is get the transmission programmed with the latest and greatest software... I know when I did the programming, it took about 45 minutes and I am using the slower ICOM compared to the updated equipment they now have at the dealer...

I said all that to ask this:

How much did it cost to program the computer? I can imagine the EGS, install, and fill with new fluid would be the substantial part of your repair that cost you $850... Did they break it down to each part? How long did it take to do the programming?

I went to the dealership today to just get this headache over with... I'm so close to getting this saga finalized... They wanted to charge me $230 to program the trans computer and EGS... Is this logical?

Thanks!!

Cheers!!
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2001 E39 540i Sport 6 speed (10-12-2000 build date) Anthricite exterior / Tan interior (Zippy)
2001 E53 X5 4.4i (03-07-2001 build date) White exterior / hellbeige interior (6MT swap vehicle - Manny)
2002 E53 X5 4.6is (12-20-2001 build date) Imola Red exterior / M-texture interior (Red)
2004 E53 X5 4.4i (11-18-2003 build date) White exterior / Black interior (Whitney)
2004 E53 X5 4.4i (09-29-2003 build date) Black exterior / hellbeige2 interior (NEWEST - Becky)
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  #24  
Old 04-07-2017, 07:56 AM
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Williamx5-
I don't have a breakdown for the programming cost. The Indie that completed the work guaranteed his original diagnosis and repair work. In the end, I paid for additional parts and hard cost only. The updated software programming was hard cost free to Indie and he attempted a free to me repair to fix his first repair without getting into new parts. We had to rule out corrupted software before spending more money on parts. In the end, software update did not fix my problem as the EGS/connector plate hardware was done internally. Replaced with working/used EGS.

My understanding of the programming is, there is specific adaption procedures to follow after the software update. A couple hours of labor. Thus, the dealer quote you received is not that far out of line at dealer shop rates. But, an Indie could probably do it for less as software update is basically pure profit, if they have the right equipment and software on hand.

Before paying for software update which is a 50/50 chance on fixing your problem, recommend checking around for a ZF transmission specialist to diagnosis your issues first. (Dealer's will probably not go into the issues deep enough and will just recommend new transmission or new mechatronic which both should come with new/rebuilt EGS connector plate and the new /rebuilt EGS is really all you needed)

My hunt for a new EGS lead me to the guy in Bulgaria that rebuilds them and after talking with him, he assured me the circuit boards within the EGS contact plate fail 100% of the time. Sometimes the software update will restore the EGS settings and bring it back to life for a while but sooner or later, you should expect the hardware within the EGS will fail.
(Best described to me: Think of an old computer that is running poorly. You can do a hard reboot or even software upgrade and it will run better. But, sooner or later the computer chip hardware will wear out and no hard reboots and software updates will be able to fix the hardware issues)

The rebuild in Bulgaria cost is $370 including shipping. They also update the software and the EGS would be plug and play for you. That might be a better option rather than 50/50 chance with dealer software update for $230.
Only reason I did not go this route was the time. 3 days there, 2 days repair & 3 days return shipping. I will be sending my old unit to them for rebuild soon. That way, I have one on hand for the future failure of my current installed used/working EGS. Probably will swap it out at the next fluid change just to get it behind me.
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  #25  
Old 04-07-2017, 06:39 PM
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Thanks! I already replaced the EGS and did the initial software install... I figured the software loaded was just old and the dealer would have newer version... I may go back in and program it again with what I have or try to get a newer version... my original problem was the failed EGS chip and I too found the rebuild guy in Bulgaria... I just pulled a used EGS from a 2006 and programmed it... no more trans failure program but not shifting like it should...

I am seriously to the point of just ditching the auto in favor of the MT6 swap... I was wanting to do this to a pre-facelift version, but the 2004 might force me into rethinking that... the bad part is that I already have two complete older (pre-face lift) sets ready... but no newer sets completed yet...

Thanks again!

Cheers!
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2001 E39 540i Sport 6 speed (10-12-2000 build date) Anthricite exterior / Tan interior (Zippy)
2001 E53 X5 4.4i (03-07-2001 build date) White exterior / hellbeige interior (6MT swap vehicle - Manny)
2002 E53 X5 4.6is (12-20-2001 build date) Imola Red exterior / M-texture interior (Red)
2004 E53 X5 4.4i (11-18-2003 build date) White exterior / Black interior (Whitney)
2004 E53 X5 4.4i (09-29-2003 build date) Black exterior / hellbeige2 interior (NEWEST - Becky)
BMWCCA member (#4745)
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  #26  
Old 06-18-2019, 12:16 PM
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Trans failsafe prog

Havng the same issue what is the "adoption process "i am 5he 3rd owner the dumb ass i got it from i am still fixing stuff. It has 207Kish on it. Was running and shifting fan... fucking...tastic. my girlfriend went to get it in the parking lot of the VA to get me after surgery and when get in she said it was acting up and the TFP come on..... I have done everything I found on here and other forms. I know she has alot of milez on her but she was shift sweet. I truly believe and feel its not the trans.....I build and restore cars for a living and drive only bmwers, so i know my was around them but the trans is my weak point. I do have PA soft win7. Please help....i need my baby back.
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  #27  
Old 06-18-2019, 12:25 PM
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Quote:
Originally Posted by Maindog View Post
Havng the same issue what is the "adoption process "i am 5he 3rd owner the dumb ass i got it from i am still fixing stuff. It has 207Kish on it. Was running and shifting fan... fucking...tastic. my girlfriend went to get it in the parking lot of the VA to get me after surgery and when get in she said it was acting up and the TFP come on..... I have done everything I found on here and other forms. I know she has alot of milez on her but she was shift sweet. I truly believe and feel its not the trans.....I build and restore cars for a living and drive only bmwers, so i know my was around them but the trans is my weak point. I do have PA soft win7. Please help....i need my baby back.
Try unplugging the natural safety switch, clean the connectors and plug it back in and see what happens.
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  #28  
Old 06-18-2019, 01:13 PM
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Quote:
Originally Posted by Maindog View Post
Havng the same issue what is the "adoption process "i am 5he 3rd owner the dumb ass i got it from i am still fixing stuff. It has 207Kish on it. Was running and shifting fan... fucking...tastic. my girlfriend went to get it in the parking lot of the VA to get me after surgery and when get in she said it was acting up and the TFP come on..... I have done everything I found on here and other forms. I know she has alot of milez on her but she was shift sweet. I truly believe and feel its not the trans.....I build and restore cars for a living and drive only bmwers, so i know my was around them but the trans is my weak point. I do have PA soft win7. Please help....i need my baby back.
Best wishes for a speedy recovery for you and your car.

The trans failsafe prog is a safe mode the AT goes into when something detects something wrong. It may have nothing at all to do with the AT. A loose / disconnected / failed MAF plug will do that. I have sometimes driven test drives with the MAF purposely disconnected while testing for something else. Due to the MAF gone, the system triggers the trans failsafe, and I can definitely feel the AT acting and shifting differently.

So my basic advice is to search for the problem, but don't limit yourself to thinking there's something wrong with your AT. More likely to be somewhere else.
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