All in - pulling the 4.6 engine and trans to fix oil leaks once and for all

[stunt]

Originally Posted by SlickGT1

You know, you just reminded me of that lurch jerk 2-1. Mine has gone away completely after the fluid change and new solenoids.

Solenoids huh? I'll have to inspect mine carefully. Those are one item I was hoping to not replace!

[kesslerbmw]

Oh come on, you're this deep... why not spend a little more!

This is the same mentality I've been in for over a month. I'm a do it yourself'er down except to rebuilding an auto trans (but I may be up to it with the info provided here) and I recently bought a 4.4 for my wife and I've paid a really good indy shop to replace every seal on the motor, timing chain guides, valley pan etc etc etc. Every time I call him I say... oh, what the hell, you're in there. lol

If it wasn't for my current work situation and weather I'd be doing it all myself, and enjoying it, but whew its breaking my wallet, and he's giving me a hell of a deal.

I've got an e34 I've had a long time, and shortly after buying it, I had every thing out of the car except for the main harness, doors, sunroof cassette, and front and rear subframes. Including doing an Auto to Manual trans swap, and swapping every other thing to the way I wanted. Even the heater core and some of the blend door/boxes. I love the projects as they give you real peace of mind that things are right, and that you're not afraid when they break way down the road. I really appreciate your documentation, I'm terrible with that. Can't thank you enough for quality pictures.

[kesslerbmw]

Oh come on, you're this deep... why not spend a little more!

This is the same mentality I've been in for over a month. I'm a do it yourself'er down except to rebuilding an auto trans (but I may be up to it with the info provided here) and I recently bought a 4.4 for my wife and I've paid a really good indy shop to replace every seal on the motor, timing chain guides, valley pan etc etc etc. Every time I call him I say... oh, what the hell, you're in there. lol

If it wasn't for my current work situation and weather I'd be doing it all myself, and enjoying it, but whew its breaking my wallet, and he's giving me a hell of a deal.

I've got an e34 I've had a long time, and shortly after buying it, I had every thing out of the car except for the main harness, doors, sunroof cassette, and front and rear subframes. Including doing an Auto to Manual trans swap, and swapping every other thing to the way I wanted. Even the heater core and some of the blend door/boxes. I love the projects as they give you real peace of mind that things are right, and that you're not afraid when they break way down the road. I really appreciate your documentation, I'm terrible with that. Can't thank you enough for quality pictures.

[RRPhil]

Originally Posted by stunt

Solenoids huh? I'll have to inspect mine carefully. Those are one item I was hoping to not replace!

We need to be careful not to tar with the same brush the 5HP24 and the 6HP26 transmissions here.

Certainly the 6-speed transmission has an increasing number of issues relating to the performance/durability of the Mechatronic unit EDS solenoids (particularly 3-4 shift problems)



Solenoid issues are, on the other hand, very rare for the 5HP24. They certainly don’t need replacing as a matter of routine (assuming the transmission was performing fine before removal?)



Phil

[stunt]

Thanks Phil.

I don't think I have provided a chronological account of my transmission issues in this thread, so let me do that now.

• 2/2013 133k Purchased X5
• 8/2013 134k Dropped transmission pan and changed the filter and did oil change (ZF Lifeguard)
• 10/2013 136k Getting "TRANS FAILSAFE PROG" when starting cold. No issues when starting warm but did notice rough 2-1 shift
• 12/2013 138k Checked fluid level and it was 1 quart low. I topped it off, but still getting "TRANS FAILSAFE PROG" when cold
• 1/2014 138k Getting "TRANS FAILSAFE PROG" now also when hot
• 3/2014 138k I drained the transmission oil and it was black and smelly

[BigBlack48is]

Stunt.... I would just rebuild it since you already have it out.

No special tools are needed, just some room for the rebuild and make sure you keep everything CLEAN CLEAN CLEAN!! ( JagRepair.com - Jaguar Repair Information Resource )

there are links @ the bottom with full howto's

I was fully planning on rebuilding mine, but I got lucky... I changed the filter / fluid at 100k miles and it has been treating me very good since! I plan on doing it again at 150k

[stunt]

Thanks for that link bigblack! I hadn't come across that one before.

I do intend to rebuilt the transmission. Just shipped off the converter this morning and will begin tearing the transmission down this weekend hopefully.

[Ricky Bobby]

This is going to be one hell of a bulletproof 4.6iS when finished stunt.

I hope you are either keeping it or to be honest the right buyer would definitely pay good money for the piece of mind.

[BigBlack48is]

Now if you want bullet proof.... go with this!

Level 10 PTS Bmw Automatic Bulletproof Rebuilding Kit

[stunt]

Yeah, that looks like it would be bulletproof! But pricey.

I spoke to Eriksson again about cost of various parts that I need and here's the list w/ part numbers. Hopefully I won't need everything, but I'll know more after I tear the tranny down.



Most of this is what Phil already suggested and he already knew the needle roller bearing part number before I complete that sentence, lol.

He also recommended getting the F piston. This has a molded rubber surround and they often find they have to replace it.

He said to inspect the main pressure regulator bore in the valve body. Often a groove will be worn in it as a result of spending a lot of time cruising at the same speed (rpm), typically 2200 rpm. What will happen is when accelerating from that cruise and a downshift occurs, the pressure regulator piston will get stuck in the grove, and rather than maintain an oil pressure of about 200 psi, it will rise to 550 psi by 3000 rpm, which is not good for the transmission.

If there is a groove, Option 1 would be to replace the valve body at a cost of about $260, or the bore can be reamed out and a slightly larger main pressure valve piston can be fitted. The cost of the 2nd option is $125.

He also said to check that there is no crack in the valve body where the part number is stamped in it. If that is the case, that kind of dictates which option to take with the above mentioned issue.

Finally, on the 3 tools to release the clutch springs, I got a quote from a local metal fabrication shop. They would waterjet cut the 3 "rings" out of 1/2" steel and then use 1/2" round steel for the uprights and 1/2" by 3/4" for the cross member portion of the handles.

Cost would be $120 per tool ($360 total) and $5 extra per tool to have them powder coated black medium texture. I asked Eriksson about the cost of those tools from ZF and he laughed and said the cost would be much higher.

I'm wondering if there would be interest in having a small run of these tools made as the price would go down quite a bit since almost all the cost is in setup/labor, not the material cost (the 3 rings would all be concentrically cut from a single 1/2 stock).

I wish I could do metal work myself and make something up. I did pick up a shop press, so I just need some means of pressing those clutches down.



Once I get the assemblies out of the transmission, maybe I'll be able to figure out a way to get the clips out without those custom made tools?