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  #21  
Old 06-21-2020, 02:24 PM
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samuelis01 is on a distinguished road
Guys thank you really much for responses. I really appreciate it.
So I also I have bought same transmission from junkyard for 20€ thinking that something may come handy.

I have disassembled couple minutes it and discovered interesting thing. Drum of coast clutch is slightly narrower than one from my transmission and it allows 4 pairs of clutch plates for forward clutch to be used instead of 3. So I am definatelly using that part instead. Otherwise that junkard tranny is shot everything is worn badly I was hoping for good forward clutch plates but whatever. At least I have that one better part (and screws )

So I have ordered 4 pairs of forward clutches, teflon shaft seals and paper seals for valvebody.

My pump and regulating valve looks literally as good as new so I am not going to mess with that.

As soon as the components arrive I will put it togheter and let you know, hopefully it will work as good as new.

Also here is link for rebuild maual, maybe ti will be useful for somebody its much more rigorous than one from redraptor : https://shop.ukrtrans.biz/wp-content...logs/5L40E.pdf

Car has 350 000km but trans had to be overhauled already. There were signs of previous disassembly and torque converter was for sure repaired also (non OEM welds)
I will take a look on that thermostat thx for tip .
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  #22  
Old 06-21-2020, 02:37 PM
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Ahh if the trans has been apart already and you think it was the wrong part that would defiantly explain why it was damaged then! If that 3 thick pack was too thick/too thin for what should be a 4 thick clutch pack that would explain the burning.

At a guess the clamping force wouldn’t have been strong enough allowing the clutches to slip, heat up and wear. Leading to seizure. Maybe the part is correct but they forgot to fit a clutch or plate?
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E53 3.0d Sport 119,000 Miles
E61 535d Estate - Hybrid turbos and Dark-side intercooler...389hp,792nm
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  #23  
Old 06-21-2020, 02:51 PM
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No no, maybe I have explained it wrong. I am just learning english

My x5 had forward drum that was meant for 3 clutch pack pairs an 3 were correctly installed. But it burned to the point of metal melting toghether.

Junkyard one has slimmer coast clutch drum that allows one more forward clutch pack pair to be fitted while maintaining same coast clutches amount. It is stronger part ( maybe later reviesion ? )

I will use the one that holds more clutches, hopefully it will help
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  #24  
Old 06-21-2020, 03:10 PM
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Ahhh okay that makes sense.

Well if it’s a revised part 100% put it in, car manufacturers won’t revise a part worse. And equally will only revise a part that needs fixing!
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E61 535d Estate - Hybrid turbos and Dark-side intercooler...389hp,792nm
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  #25  
Old 06-21-2020, 06:15 PM
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Are both models version ‘G’ or is one a ‘Z’?

Name:  GM G or Z.jpg
Views: 38
Size:  358.0 KB

Phil
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  #26  
Old 06-21-2020, 06:25 PM
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Ahhhhh that’s why the gearbox is rubbish........ not only is it GM...... it’s also made in France!!



Only Joking the french make great cars..... And I drive a Range Rover with an engine even Buick thought was rubbish so what do I know lol
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  #27  
Old 07-03-2020, 03:24 PM
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Update:

So after all that effort, repair sadly was not succesful.

I have been driving the car for past week or so after replacing burned forward clutch and something is still wrong.

I can drive it like if I stole it all day, works perfect shifts are fine.
But the problem happens if I drive uphill at about 30% throttle - about 90kmh

Once it attempts to shift into 5th something weird happens and transmission goes into limp mode. Thorwing code: 55 "gangueberwachung 5 " which is based on my research basically an incorrect gear ratio for 5th gear.

Never goes into limp mode or misbehaves if I only apply light throttle or beat on it hard so it stays in first 4 gears.

I have inspected all of the clutch discs before assembling the transmission and they were fine.

Replacement of forward clutch was fairly straight forward and everything made sense so we were able to diagnose it 100% correctly toghether.
But now I have honestly dont know what can cause this. Any ideas on this ?

Is the 5th clutch in fact slipping ? i do not understand this.

Thank you guys very much
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  #28  
Old 07-03-2020, 06:42 PM
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None of the three shift solenoids are activated in 5th gear so it’s unlikely to be a solenoid issue. Are you getting engine braking in Manual 3rd gear? The reason I ask is that the overdrive clutch is applied in 5th gear (i.e. on the 4-5 upshift) but it is also engaged in Manual 3rd gear to provide overrun braking. The overdrive clutch is the one immediately behind ‘the-mother-of-all-circlips’ (you’ll know the circlip that I mean).





Phil
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  #29  
Old 07-04-2020, 06:31 AM
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Thank you for response Phil. I have for sure inspected clutch discs of the clutch you mentioned. They were fine barely worn if at all. I sure know that circlip, even had to make huge pliers jus for it.
Today I have checked fluid again, I was able to get about 0.5L more inside (engine running, transmission in park ).
I almost thought that this cured the problem as I did about 60km without limp mode. Shifting completelly fine. Tried every possible driving mode including highway. It does shift into 5th and does stay in it with no slipping. I have verified it with diagnostic hooked and laptop next to me while looking what gear is engaged. I have shifted 4-5 and 5-4 manually many times and nothing happened.
But then at steady speed about 60km/h, flat surface limp mode again... Im pissed

And yes, I am getting engine braking in 3rd fine, everytime.

Im thinking of purchasing reconditioned velvebody to rule this out. But then again this fault was not in the error memory back when forward clutch was seized. So it is probably something that I have done.

I have disassembled the valvebody, cleanded it and assembled back toghether with new seals and accumulator springs. All of the balls are placed correctly for sure.

do you think that something like this would be a good idea or is it not worth the risk buying from china : https://www.ebay.com/itm/5L40E-Trans...Condition=1000

Also I have seen your autopsy of same thransmission on Range rover forum. Good job documenting I have to say I have plenty equipment, I can even machine my own oversize valves, bore the valvebody etc.. I just dont have any experience with automatic transmissions, this is my first time messing with it.

Last edited by samuelis01; 07-04-2020 at 06:50 AM.
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  #30  
Old 07-04-2020, 07:04 AM
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I am wondering if there could be possible leak here: (circled in the image)
causing sporadic 5th clutch slippage resulting in limp mode.
I have not replaced this rubber part.

I am willing to ramove and disassemble that piece of shit one more time even replace all of the clutches if that is necessary.. I can get exedy branded set of cluthches for about 280€ but generally I really dont like blindly replacing parts that still have life in them and those overdrive cutches really seemed fine to me.
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Last edited by samuelis01; 07-04-2020 at 07:13 AM.
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