2001 4.4 transmission issues

[gpeterson]

I recently bought a 2001 E53 4.4 with known transmission issues. It will slip in 1st gear maybe 1 out of every 10 times I accelerate from a stop. If I back off the throttle it will usually catch and I can accelerate. Occasionally it goes into trans failsafe mode. I get EGS gear monitoring codes (31, 34, 35) and IKE: EGS signal line disturbed (8D). Here is what I've tried so far:

-Checked trans fluid level (using proper ZF procedure). PO says fluid & filter were recently changed as an attempt to fix the issue

-Checked voltage when running. PO replaced battery & alternator as an attempt to fix the issue

-Replaced instrument cluster (speedo needle was stuck on the old one)

-Unplugged trans valve body connector and gear position switch connector, inspected/cleaned contacts

-Unplugged DME & EGS, inspected/cleaned contacts.

-Cleaned MAF (although I haven't had any DME codes)

-Reset transmission adaptation using INPA

-Swapped in spare EGS module

-Pulled the 3 DSC fuses (since I heard bad DSC can disrupt the CAN bus). I have not yet tried unplugging the DSC module, will do that soon. INPA reports DSC clamp 15 voltage at around 12v. Seems odd. DSC has had code 5A (DSC: brief power interruption) twice.


Any thoughts? Could a transmission mechanical issue be so intermittent? When it isn't freaking out it shifts well. I'm thinking/hoping it is an electrical issue, especially with the 8D "IKE: EGS signal line disturbed" and the occasional 5A "DSC: brief power interruption".

[RRPhil]

1st gear on the 5HP24 uses the A-clutch and the F-brake sprag. The A-clutch is also used in 2nd, 3rd & 4th gears. If you select 1st gear in Manual mode the F-brake is applied and this will by-pass the sprag. I should use manual mode for a while and see if the problem disappears. If so, it would indicate that the sprag’s at fault.









Phil

[///Monster123]

Is the transmission slipping worse when the transmission fluid is warmed to operating temp?

[gpeterson]

Originally Posted by RRPhil

I should use manual mode for a while and see if the problem disappears. If so, it would indicate that the sprag’s at fault.

Thanks for the info! I *think* it happened once I manual mode, will try again. If the problem does occur in manual mode what do you think the issue may be?

Originally Posted by ///Monster123

Is the transmission slipping worse when the transmission fluid is warmed to operating temp?

Seems like it, but the issue is intermittent.

[upallnight]

Originally Posted by gpeterson

Thanks for the info! I *think* it happened once I manual mode, will try again. If the problem does occur in manual mode what do you think the issue may be?



Seems like it, but the issue is intermittent.

You have an internal fluid leak. This can be a cracked drum or a bad o-ring. Either way, the trans needs to come out and disassemble and whatever is worn or broken needs to be replaced.

[gpeterson]

Wow, lots of good info here already. I'll probably pull the transmission this weekend. Who is a good US vendor for 5HP24 parts? I'll probably order at least a rebuild kit and see what else I need once I open it up.

Would this be a good minimal parts start?

https://www.fcpeuro.com/products/bmw...05829802201#qa


Is this the manual I need?

http://www.jagrepair.com/images/Auto...r%20Manual.pdf

A lot of special tools listed, but it sounds like you can get away without them.

[upallnight]

That just gasket and o-rings. If you have a cracked drum that will be an additional part. That also doesn't include any friction material. or valves, or solenoids for the valve body.

[gpeterson]

Originally Posted by upallnight

That just gasket and o-rings. If you have a cracked drum that will be an additional part. That also doesn't include any friction material. or valves, or solenoids for the valve body.

Understood, I just wanted to order the minimum that I'll need to reassemble it. I figure I'd wait until inspection to order any hard parts but am considering getting this kit - https://www.cascadetransmissionparts...allmodels.aspx. I could always order the drum if necessary.

[///Monster123]

If it slips more when warm and in manual mode I would expect a failed o-ring or destroyed A drum. My symptoms were similar to yours and my experience was a failed o-ring and bearing set.

I also ordered my kit from cascade transmission parts. No complaints.

However I decided to order from Cobra Transmission for everything else. They are great to work with and quick to reply. I recommend them 100%. Here's their info

John A.
BMW and MB Transfer Case Specialist
786-472-8500
[email protected]


RRPhil on Xoutpost is extremely resourceful when it comes to these transmissions. He's great help if you hit a snag in the rebuild.

I also recommend watching some of Gary Ferraro's 5HP24 tear down and rebuild videos on youtube. He's really thorough in his videos and quick to respond if you get a question on the 5HP24.

As far as tools go, you'll want to look into a generic clutch spring compressor. I picked one up from harbor freight and I was able to make it work for most things but I did have to get creative for one of the clutch springs. I used a 2x4 with several screws set to equal lengths around a circle the size of the clutch spring tongues. Not pretty but it worked. I don't think I needed any other special tools.

Good luck!

[gpeterson]

Thanks, good info. I was going to wait on some parts until I had the transmission apart but decided to get the master rebuild bundle (rings, seals, gaskets, friction material, steel plates, F clutch piston, alligator input clutch drum, Transgo pressure regulator valve upgrade, Filter) from Cascade. They don't list the needle bearing but I'll get one from Cobra for $40. Not sure if I need it, but may as well replace if I'm going this far. Should I get a torque converter as well?