Launching "Operation Fix the Transmission" ... SUCCESS!!

[X5chemist]

Ha! I'll be using the same Harbor Freight pump. I'm setting mine up on four ramps. I'll use a 6 ton jack to lift it up. 6 ton jack stands will serve as back up.

[haigha]

I used my trusty MityVac 7201 and the side port on the transmission. I filled it with 8L of fluid and put almost all of it back in. I think it's a lot easier than trying to fill from the port on the bottom. From what I could determine, the side port is at the same level as the top of the tube on the bottom fill port.

My friend, who was a BMW Master tech, said they did it that way at the dealer, but he had left the dealer about a decade before this model came out.

[X5only]

Originally Posted by haigha

I used my trusty MityVac 7201 and the side port on the transmission. I filled it with 8L of fluid and put almost all of it back in. I think it's a lot easier than trying to fill from the port on the bottom. From what I could determine, the side port is at the same level as the top of the tube on the bottom fill port.

My friend, who was a BMW Master tech, said they did it that way at the dealer, but he had left the dealer about a decade before this model came out.

There was mention on a post in this forum a while back that filling from the side on a GA6HP26X could result in a 1 quart overfill. But I was curious and couldn't find any side plug. In any case, I didn't find it hard to fill from the correct fill hole which is on the pan- just need to locate inside the fill hole with your finger the gap in the standpipe (two of them) and push in your oil hose in one of them.

Here's a video showing it.
https://www.youtube.com/watch?v=jjdjqDqgLj0

[haigha]

Good advice! Better to do it the way the manual states.

The good news is that I haven't had any problems since using the side port. It's on the passenger side (LHD).

I wonder if 1 qt over would do any harm? I had read one place in my research that they are slightly overfilled at the factory.

[X5only]

Awesome👍. Is it the #2 side port in this diagram? It may be quicker with that port especially if you’re trying to stay below the 50c max oil temp. I’m not sure if it was regarding the E53 or F85 X5, but there was a recommendation to overfill a bit if doing lots of steep up-hill/down-hill, may be engine oil and not trans oil?

[haigha]

Yes, it's #2! Being an amateur, I ripped off half of one of my nails when trying to loosen it, before my friend came over. My gloves were right next to me

I replaced the bolt.

The reason I loosened it myself was I used the drain plug on the bottom to get the old ATF out for several days before he came over. I saw in the instructions that it's important to make sure you can open the fill hole before draining.

[X5only]

Update: Got this done with lots of drama, all my foolish self being overconfident - what should have been a day's operation turned out to be almost 4 days - I had to redo twice due to silly mistakes . Learned hard lessons for the rest of us DIY'ers. I'll put up a little gotchas writeup that I should have known better. Otherwise, it' not a tough job compared to something like valve stem seals. Pics coming ...

[wpoll]

[haigha]

Good to hear you got it done I'm hoping not to have to tackle mine a third time.

[X5only]

Ok, boys, final report. First and foremost, good news - there were no metal shavings in the oil (other than the muddy stuff captured by the oil pan magnets), so that was great. I've fallen in love with my X5 all over again, she's driving like new much like when I first got her. It's been over 10 years since this car has driven this good. It does feel peppy with no hesitations and delay in gear changes. Hitting WOT when joining the freeway delivers smooth and authoritative power, wow . With the 3 fluid changes and new parts, I think I'm good for the next decade. The final oil drain quality was great - mostly clear pink. But this time around I'll do fluid change may be every 30k miles as a matter of preventative maintenance. When doing engine oil changes, include transmission inspection for leaks as part of undercarriage look-see .

There're lots of DIY videos and instructions for the X5 6 speed (see initial post), but here's my feedback on my experiences that I wish I knew before starting the project:

1) Even if you've done transmission rebuild previously, unless you're a pro who does it frequently, please review what needs to be done. Do not be overconfident while relying on your recollection of the previous rebuild you did. You're bound to forget some critical step. Fortunately for me, they were reversible, thankfully. I strongly recommend watching the videos fully and go through the instructions carefully. Don't just scan through them!

2) Patience, patience and more patience. Take your time and never be in a hurry. Stop and review your work before buttoning anything up, at every step of the way.

3) Use the long and curved needle nose pliers (Harborfreight tools has them) to remove the mechatronic wiring harness sealing sleeve. When installing it, remember to lube the sealing sleeve with trans fluid - it will slip right in without much effort.

4) Before installing the trans oil sump back, stop, take a break and then review your work - is the oil filter installed (), is the gear selector rod properly positioned on the mechatronic and the transmission (the car would not start if improperly installed), etc. It will save you a lot of aggravation and time, trust me on that one .

5) I was very impressed by the performance of that simple and cheapo $8 Harborfreight fluid transfer pump. Simple yet very effective. I could transfer a gallon of oil in less than a minute in a very controlled fashion. It works both ways- as a fluid transfer and as a fluid extractor. Very effective both ways. I installed hose clamps on the hose joints for extra assurance. Worked amazing, especially when monitoring the oil level and adding just a little bit more in a very controlled manner!

I've attached some ZF docs that provide the detailed procedures and the sequence of tightening the screws on the mechatronic and the sump. I've also included pics of upper valve body check ball locations etc. I followed them exactly.

Docs I gathered while prepping for the mission:

https://www.thectsc.com/images/custo...eplacement.pdf
https://www.thectsc.com/images/custo...eplacement.pdf
https://www.thectsc.com/images/custo...eplacement.pdf
https://www.thectsc.com/images/custo...eplacement.pdf
https://www.thectsc.com/images/custo...structions.pdf
https://www.thectsc.com/6-speed-tran...ange-procedure