Trans Failsafe Prog E53 3.0D

[bornonmarch]

Hi everyone

I'm new here. I have 2004 E53 3.0D with GA6HP26Z transmission. I bought it last December when the odo was 220,500 kms and now it has 223,300 kms. We didn't use it very often due to error message.

A week after we purchased it, the car threw Trans Failsafe Prog (TFP) error randomly. And now it happens every time once the temp below a quarter mark!

What I have done to fix these are:
1. new battery with a higher CCA as the starter motor failed (later I found out my previous battery is still good and only needs a re-charging). I also replaced the starter motor with a used one.
2. Previous owner did the transmission fluid change when it was 160,000 kms. I did the change + filter at 221,800 with Mechatronic seals, adapter seal and 4 sealing seal. This was done at 40C.
3. Replaced the transfer case fluid (BMW) + rear differential fluid at 221,800
4. Replaced Glow plugs + glow plugs controller (Inpa shows error for this too).
5. Replaced with a used gear selector unit (GT1 shows 5088 gear selector error).
6. Replaced new automatic transmission thermostat + expansion radiator tank.

But none gives me a permanent fixed. I can use reverse gear even the error appears. When errors appear it sticks to D only, S or M won't engage. When the error appears, it will trigger the error only on D (even when engine is not running and moving the gear selector to D would trigger the error).

Yesterday I got the error code around a quarter of temp. gauge and drove it at 60 kms for 30 mins, stopped to pick up item for app. 10 minutes. Drove it again without any error at all.

Today I drove it and same condition, a quarter mark the error popped up. I stopped but it didn't fixed the problem. Did this around 10 times but no luck. Every time I turn off the engine and start the car, it won't throw the error until it moved to 'D'. I monitored the transmission fluid when it reached 102C (engine temp was around 66 - 75C), and I started the car again (no error yet) and moved the gear selector from P, R and N only, back and forward for 3 - 4 times, and then put it to D - no error message. The transmission fluid temp was around 97C when it finally engaged to D without error.

Drove it again later on this evening and a quarter mark passed but no error. Put diagnostic (inpa & GT1), but couldn't figure out.

Here is the inpa report:

E R R O R M E M O R Y R E P O R T
-------------------------------------
Date: 09/18/16 13:47:21
ECU: D_EGS
JobStatus: OKAY
Variant: GS19A
-------------------------------------------------------------
RESULT: 1 errors in error memory !
-------------------------------------------------------------
20616 clutch choice Sensors wrong
Warning: F_HFK doesn´t exist in result record 1 !
Warning: F_UW_ANZ doesn´t exist in result record 1 !
Warning: F_ART_ANZ doesn´t exist in result record 1 !
Errorcode: 50 88 28
================================================== ===========
Ecu : D_0056 IFH-0009: NO RESPONSE FROM CONTROLUNIT
================================================== ==================================
Variant: D50M57B1 1 Error in error memory
Error registration 1 : 0x4B10: 4B10 (1278) engine-roughness regulator <<<<!!!
Error accurances: 4B10 (1278) engine-roughness regulator
Error code: 4B 10 31
================================================== ==================================
Variant: LWS5_1B >>>>>>>>>> No error found <<<<<<<<<<<
================================================== ==================================
Variant: D_00AC -1 Error in error memory
================================================== ==================================
Variant: D_0070 -1 Error in error memory
================================================== ==================================
Variant: LCM_IV >>>>>>>>>> No error found <<<<<<<<<<<
================================================== ==================================
Variant: D_0066 -1 Error in error memory
================================================== ==================================
Variant: D_009A -1 Error in error memory
================================================== ==================================
Variant: RLS_DS2 >>>>>>>>>> No error found <<<<<<<<<<<
================================================== ==================================
Variant: D_0008 -1 Error in error memory
================================================== ==================================
Variant: EWS3 1 Error in error memory
Error registration 1 : 0x000F: power on reset <<<<!!!
Error accurances: 1
Static error
Error code: 0F 21
================================================== ==================================
Variant: ZIS 1 Error in error memory
Error registration 1 : 0x0003: no valid status response of TELEPHONE <<<<!!!
Error accurances: 2
Error present
================================================== ==================================
Variant: ZKE3_GM6 >>>>>>>>>> No error found <<<<<<<<<<<
================================================== ==================================
Variant: D_SZM -1 Error in error memory
================================================== ==================================
Variant: MRS4 >>>>>>>>>> No error found <<<<<<<<<<<
================================================== ==================================
Variant: IKI 2 Error in error memory
Error registration 1 : 0x00BD: EBV <<<<!!!
Error accurances: 35
--
--
--
--
--
Sporadic error
error external ECU
Error code: BD 90 23
------------------------------------------------------------------------------------
Error registration 2 : 0x008D: ATS signal: telegram error or no telegram <<<<!!!
Error accurances: 158
--
--
--
--
--
Sporadic error
error external ECU
Error code: 8D 90 9E
------------------------------------------------------------------------------------
================================================== ==================================
Variant: D_00B0 -1 Error in error memory
================================================== ==================================
Variant: IHKA39_5 >>>>>>>>>> No error found <<<<<<<<<<<
================================================== ==================================
Variant: ZUHEIZ >>>>>>>>>> No error found <<<<<<<<<<<
================================================== ==================================
Variant: RADIO >>>>>>>>>> No error found <<<<<<<<<<<
================================================== ==================================
Variant: D_006A -1 Error in error memory
================================================== ==================================
Variant: D_0048 -1 Error in error memory
================================================== ==================================
Variant: D_00C8 -1 Error in error memory
================================================== ==================================
Variant: D_00F0 -1 Error in error memory
================================================== ==================================
Variant: D_00ED -1 Error in error memory
================================================== ==================================
Variant: D_003B -1 Error in error memory
================================================== ==================================
Variant: D_0048 -1 Error in error memory
================================================== ==================================
Variant: D_007F -1 Error in error memory
================================================== ==================================
Variant: D_00BB -1 Error in error memory
================================================== ==================================
Variant: D_SITZ_B -1 Error in error memory
================================================== ==================================
Variant: D_SITZ_F -1 Error in error memory
================================================== ==================================
Variant: SM53_4 1 Error in error memory
Error registration 1 : 0x0011: steering-column radial, Transmitting-error <<<<!!!
Error accurances: 1
Static error
Error code: 11 21
================================================== ==================================
################################################## ##############
This content will stored temporary temporär in ..\inpa\sgdat\na_fs.tmp
################################################## ##############

Any clue?? Many thanks for the input

[bornonmarch]

Forgot to add, I also replace the electric fan as it failed when the aircon is on. My mechanic told me that the trans fluid was short and he added another couple litres but it didn't fix the problem either. I re-checked the trans fluid level at home and set it up level and working temp at 40C, when I opened the fill bolt it was over-filled by almost 2 ltrs. So my mechanic might be wrong when adding it up. Strange thing is the colour of the over-filled fluid is dark brown (considering I changed it less than 3000 kms). This prompted me that the fluid might be over-heating and decided to change automatic transmission thermostat. But this didn't fix the issue either.

GT1 shows 5088 EGS: sensors, transmission switch L1 - L4 - line coding of position sensor is implausible. Followed the test on GT1 to see the value of L1 - L4. The values changed when selecting P, R, N, or D. GT1 concludes no further test can be performed.

Any suggestion please?

[deepblonde]

Originally Posted by bornonmarch

Hi everyone

I'm new here. I have 2004 E53 3.0D with GA6HP26Z transmission. I bought it last December when the odo was 220,500 kms and now it has 223,300 kms. We didn't use it very often due to error message.

A week after we purchased it, the car threw Trans Failsafe Prog (TFP) error randomly. And now it happens every time once the temp below a quarter mark!

What I have done to fix these are:
1. new battery with a higher CCA as the starter motor failed (later I found out my previous battery is still good and only needs a re-charging). I also replaced the starter motor with a used one.
2. Previous owner did the transmission fluid change when it was 160,000 kms. I did the change + filter at 221,800 with Mechatronic seals, adapter seal and 4 sealing seal. This was done at 40C.
3. Replaced the transfer case fluid (BMW) + rear differential fluid at 221,800
4. Replaced Glow plugs + glow plugs controller (Inpa shows error for this too).
5. Replaced with a used gear selector unit (GT1 shows 5088 gear selector error).
6. Replaced new automatic transmission thermostat + expansion radiator tank.

But none gives me a permanent fixed. I can use reverse gear even the error appears. When errors appear it sticks to D only, S or M won't engage. When the error appears, it will trigger the error only on D (even when engine is not running and moving the gear selector to D would trigger the error).

Yesterday I got the error code around a quarter of temp. gauge and drove it at 60 kms for 30 mins, stopped to pick up item for app. 10 minutes. Drove it again without any error at all.

Today I drove it and same condition, a quarter mark the error popped up.

Any clue?? Many thanks for the input

Are you saying the error appears when the the trans is cold or when it warms to at least a quarter?

[wpoll]

There's a change in the shift logic at about a 1/4 warm - the higher gears are disabled up to this temp - I wonder if that is somehow related...?

[bornonmarch]

It starts fine. The problem will kick-in when the temp. gauge close to a quarter mark (usually both trans. fluid and engine temps are at 55C).

[wpoll]

Originally Posted by bornonmarch

It starts fine. The problem will kick-in when the temp. gauge close to a quarter mark (usually both trans. fluid and engine temps are at 55C).

Sounds about exactly when the different shift logic kicks in..

I don't know which higher gears or "unused" at low engine temps - but perhaps the first solenoid related to these higher gears is faulty?

I know that when my 3.0d with a GA6HP26X gets to those temps, I can feel it kick up a gear and the revs drop accordingly. It's usually a about 1.5-2kms from home.

[bornonmarch]

Wpoll, did you have a similar situation like mine? How did you fix it? What do you mean with 'shift logic'?

[wpoll]

Originally Posted by bornonmarch

Wpoll, did you have a similar situation like mine? How did you fix it? What do you mean with 'shift logic'?

Nope - not had this issue so I can't be sure of the fix.

Shift logic is the set of rules used in the programming of the transmission controller, to determine when gear shifts should be made. Multiple parameters are taken into account (RPM, engine temp, trans temp, throttle position, engine load etc.) and the shift logic rules define what happens at any given time.

Below about 50-55 Deg. C (engine temp) the shift logic will not allow the transmission to shift into top gear. This is to keep engine RPMs high enough to quickly warm the engine and also to avoid have a large torque load placed on the cold engine. Pretty much all auto shift logic systems do this, not just BMW/ZF.

I thought it interesting that your fault occurs exactly as the shift logic changes and allows the transmissions to shift into top gear. It kinda indicates that the components associated with top gear are the issue. I wonder if you drive slow enough, and let the engine get warmer than 50-55 Deg. C if the error can be avoided by avoiding speeds that cause the transmission to shift into top gear. Just as a diagnostic process - not as a normal driving method! Given that your fault is somewhat intermittent anyway, this maybe be of limited value. Also the fact that you can provoke the trans. fail-safe mode when not even moving indicates that the issue is a complex one!

It would be worth measuring the resistance values of the solenoids at both cold and warm trans temps. You can do this via the mechatronic connector. It might show up something? Maybe the solenoid for 6th (or one of the associated brakes) is going open circuit at warmer temps.

[bornonmarch]

My wife usually drives the car to take the kids to school. The route she took has 80 km speed limit and the morning traffic condition was usually at peak, so I would say on average it would run on 50 - 60 km. The error happened usually after 15 - 20 minutes of driving at this speed.

When the error happens, it only feels a bit sluggish when it stops. It still has a plenty of power (although with higher RPM). Previously it was very bad, but my mechanic found a leaking vacuum tube which remedied the loss of power (even when it's in TFP stage).

I'm going to run the resistance test on Mechatronic connector tonight. Thank you anyway.

[wpoll]

Originally Posted by bornonmarch

My wife usually drives the car to take the kids to school. The route she took has 80 km speed limit and the morning traffic condition was usually at peak, so I would say on average it would run on 50 - 60 km. The error happened usually after 15 - 20 minutes of driving at this speed.

When the error happens, it only feels a bit sluggish when it stops. It still has a plenty of power (although with higher RPM). Previously it was very bad, but my mechanic found a leaking vacuum tube which remedied the loss of power (even when it's in TFP stage).

I'm going to run the resistance test on Mechatronic connector tonight. Thank you anyway.

If you can drive 15-20 minutes and it's only then getting up to 1/4 temp, I'd say your thermostat is shot. Might be a good place to start!