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Old 04-07-2020, 04:58 PM
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Angry Help Needed. Mechatronic Sleeve Shattered : | (Solved)

This happened on the wife's E70 x35d but figured I'd post here in case someone had any ideas and this does crossover to any BMW that uses a ZF mechatronic sleeve. I used a vaico sleeve (don't do this, they suck compared to ZF ones). Used a ZF one on the E61 and had no problems.

My question for the collective. How can I get that sleeve (what's left of it) out of the trans? It's broken off pretty much flush with the body of the trans now as I tried pulling with long needle nose and prying but of course the brittle plastic just continued breaking. Anyone have any secret voodoo I could try? I am not averse to dropping the exhaust for more room to work if it means avoiding dropping the valve body to try and attack from the inside. Thanks in advance for any assistance.

BTW, for anyone wondering why I would use a Vaico sleeve... It came new along with 7 liters of ZF Lifeguard 6 I bought off Craigslist. Obviously I was after the fluid but figured I'd use the sleeve since I had it. Moron. Thought I had learned the non-OE/OES parts lesson already.

Pics of the carnage:

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Last edited by crystalworks; 04-10-2020 at 04:34 PM.
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Old 04-07-2020, 05:08 PM
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The pic I am looking at has a shadow, but it appears that it’s hollow or shall I say has an opening? Hard to tell, but if so, a tool that will expand inside that opening.
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Old 04-07-2020, 05:23 PM
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It is hollow. It is supposed to look like this:



Can't really expand something in there as that will add more pressure to the O-rings and just add to their grip in the transmission. I was thinking of sticking something in between the sleeve and the trans hole to try and crack the sleeve so it will relieve pressure on the O-rings. The Vaico sleeve just isn't as well made as the ZF ones. I have ordered 2 ZF sleeves from FCP, but still have to get the remnants of the Vaico one out.

Edit: This is what the sleeve looks like uninstalled. The one in my trans is broken just in front of that first large O-ring.

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2005 X5 4.4i Build 04/05 Maintenance/Build Log
Nav, Pano, Sport (Purchased 06/14 w/ 109,000 miles) (Sold 8/15 w/121,000 miles)


2006 X5 4.8is Build 11/05 Maintenance/Build Log
Nav, DSP, Pano, Running Boards, OEM Tow Hitch, Cold Weather Pckg (Purchased 08/15 w/ 90,500 miles)

2010 X5 35d Build 02/10
Nav, HiFi, 6 DVD, Sports Pckg, Cold Weather Pckg, HUD, CAS, Running Boards, Leather Dash, PDC, Pano (Purchased 03/17 w/ 136,120 miles)

Last edited by crystalworks; 04-07-2020 at 05:29 PM.
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Old 04-07-2020, 05:29 PM
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Break it in two places, keeping debris minimal.
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Old 04-07-2020, 05:51 PM
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Just one thought. Get a cheap flat head screwdriver. Warm the end till it's red glowing. Bend the end 90 degrees on a vice so you get a hook like pulling tool. While hot push it on the inside of the sleeve to melt pulling points on opposite sites. Cool down the tool and pull the sleeve out with it.
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Old 04-07-2020, 06:17 PM
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I'm going to assume you pulled the sleeve release handle down before you are attempt to remove the sleeve. If you did not pull the handle down the sleeve is not going to come out, even with the handle down it is a tight fit. I would get a pick to pry the sleeve out.

https://www.youtube.com/watch?v=2g-5uY_P7uA
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Old 04-07-2020, 06:35 PM
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Thanks for the suggestions. Not a lot of room to work with there, think I'll try heating the long screwdriver method first and see how that goes. Would be nice to not have to remove the exhaust. I will say this, I would not worry about a fluid leak past those O-rings.

upallnight, yes ,I did release the locking latch. The "funny" part was I got it almost all the way in but could not latch the mechatronics latch for the sleeve. So I pried a little more and then the sleeve broke. Just to rub salt in my would I tried the mechatronics latch. Of course it slid right up. HAHA! Good one universe, good one.
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2005 X5 4.4i Build 04/05 Maintenance/Build Log
Nav, Pano, Sport (Purchased 06/14 w/ 109,000 miles) (Sold 8/15 w/121,000 miles)


2006 X5 4.8is Build 11/05 Maintenance/Build Log
Nav, DSP, Pano, Running Boards, OEM Tow Hitch, Cold Weather Pckg (Purchased 08/15 w/ 90,500 miles)

2010 X5 35d Build 02/10
Nav, HiFi, 6 DVD, Sports Pckg, Cold Weather Pckg, HUD, CAS, Running Boards, Leather Dash, PDC, Pano (Purchased 03/17 w/ 136,120 miles)
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Old 04-07-2020, 06:47 PM
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Quote:
Originally Posted by crystalworks View Post
Thanks for the suggestions. Not a lot of room to work with there, think I'll try heating the long screwdriver method first and see how that goes. Would be nice to not have to remove the exhaust. I will say this, I would not worry about a fluid leak past those O-rings.
I would still grind the corners of the screwdriver end a bit round so that it suits better for the curvature.

You could also use some penetrating oil to lubricate the o rings so they would slide out more easily.
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Old 04-07-2020, 06:51 PM
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Quote:
Originally Posted by Clavurion View Post
Just one thought. Get a cheap flat head screwdriver. Warm the end till it's red glowing. Bend the end 90 degrees on a vice so you get a hook like pulling tool. While hot push it on the inside of the sleeve to melt pulling points on opposite sites. Cool down the tool and pull the sleeve out with it.
Nice idea. One potential mod would be to use two of those, so they press against one another along the centerline of the part, keeping themselves in place.

But before that, I'd do a test on a piece of the cracked off plastic to see if it is a thermoplast (will melt when heated) or thermoset (will maybe burn, but will not melt at all when heated). So obviously, if it's a thermoset and won't melt, then you'd rather figure that out on a scrap on the floor rather than while looking up, struggling, etc.

Good luck.
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Old 04-07-2020, 09:35 PM
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Quote:
Originally Posted by crystalworks View Post
Thanks for the suggestions. Not a lot of room to work with there, think I'll try heating the long screwdriver method first and see how that goes. Would be nice to not have to remove the exhaust. I will say this, I would not worry about a fluid leak past those O-rings.

upallnight, yes ,I did release the locking latch. The "funny" part was I got it almost all the way in but could not latch the mechatronics latch for the sleeve. So I pried a little more and then the sleeve broke. Just to rub salt in my would I tried the mechatronics latch. Of course it slid right up. HAHA! Good one universe, good one.
Did you put any type of lubricant on the o-rings before inserting the sleeve? If not use a little bit of silicone lube the next time if you have some.
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Lotus Europa 1970 S2 Renault Powered
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PORSCHE 911 Targa 1982 The Garage Queen
Audi Avant donated to Kars for Kids
BMW 525IT Sold
Audi 4000CS Quattro Sold
Jensen Healey Lotus Powered Sold
Opel 1900 Sold
Triumph Spitfire 1971 Sold
Triumph Spitfire 1968 Sold
Plymouth "Cuda" 340 Six pack SOLD
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