Rolled the Dice, Came Up Snakeyes (4f89 Fault) Trans Replacement

[Happy]

Originally Posted by Happy

Welll... It’s always something now, huh.?

Aye, better to have a solution, then not.

That’s a lot of work man!

[crystalworks]

Originally Posted by Happy

Aye, better to have a solution, then not.

That’s a lot of work man!

Yep, engine hoist it is. My FCP order shipped yesterday so hopefully I can get the old trans out this weekend. Swap over what I need to from old to new trans and then put it in next weekend along with the new motor mounts, Xfer case mount, and various other "while I'm in there" parts.

Yes, a lot of work Happy. But the truck gave us 35000 relatively trouble free miles so she earned it. This job(s) even at an indy would run into the $6000 range... so saving us quite a bit of money by rolling up my sleeves. Just means Red has to sleep outside under the car cover for 3 or 4 weekends.

[Happy]

Originally Posted by crystalworks

Yep, engine hoist it is. My FCP order shipped yesterday so hopefully I can get the old trans out this weekend. Swap over what I need to from old to new trans and then put it in next weekend along with the new motor mounts, Xfer case mount, and various other "while I'm in there" parts.

Yes, a lot of work Happy. But the truck gave us 35000 relatively trouble free miles so she earned it. This job(s) even at an indy would run into the $6000 range... so saving us quite a bit of money by rolling up my sleeves. Just means Red has to sleep outside under the car cover for 3 or 4 weekends.

Good luck with the final stages of the repairs!

If you’re able, and a 6 grand savings. Yep, roll them sleeves up!

ReD will be fine. Hey, maybe you can share a bit of that savings with good’ole ReD. LoL...

[Mouse]

Hope to join you again next weekend. Suxors on the road block but we are no strangers to these "setbacks" are we. We'll get some progress and get her rolling again.

[jcarpfishman]

Subscribed to see how this all plays out!

I've got some wonky shifts on my '07 4.8 with the same 6HP28x. Followed roughly the same process so far with similar results: new solenoids, pan & fluid change, rebuilt valve body (also by Worldwide Specialty Parts, excellent service!) & another fluid change. Still getting regular flare shifts from 1-2 & the occasional slam shift if you punch it, but no stored codes and no limp-modes (yet).

Do you have any qualms about using one with 88k miles on it + rebuilt valve body or is so much lower than your current mileage that you're thinking is it *has* to be in better condition?

[crystalworks]

Originally Posted by jcarpfishman

Do you have any qualms about using one with 88k miles on it + rebuilt valve body or is so much lower than your current mileage that you're thinking is it *has* to be in better condition?

Pretty much. The lower mileage, combined with the rebuilt valve body/mechatronics from our current trans should be fairly equivalent to a ZF 6hp28x trans that was serviced properly (every 40-50k miles) from original in service date as ZF recommends. Shame on BMW (they're not the only ones who do it) for not following the trans manufacturer suggested service intervals.

Okay, so we hit it again this weekend. This time putting in probably around 18 hours. We are moving deliberately slowly in the hopes of not breaking any coolant lines or wiring while moving everything around. Let me tell you, that DPF requires A LOT of room to get out of there. The packaging is just insane.

Some notes and accomplishments from the weekend.

• DPF removal is 100% a must to access the flywheel bolts. TIS is laughable: "Loosen DPF V-band and push to the side to remove access panel on engine to access flywheel bolts." BS!
• Engine mount must be removed to facilitate DPF removal (2 T10? bolts and 18mm engine mount nut securing engine to mount)
• Engine must be lifted AND subframe lowered to facilitate DPF removal
• An alignment will be necessary after job completion
• Right side engine mount arm must be removed from engine (4 16mm bolts I believe)
• Lower EGR cooler must be removed from DPF to allow enough room for removal
• 100% (or felt like it) of the cooling system will drain upon removal of lower EGR cooler
• There are 3 sensors (hope they're keyed ) and 2 vaccum lines total between the EGR cooler and the DPF that must be disconnected for removal. Multiple wire brackets/clips as well.
• Right side filter housing and engine partition must be removed to gain access to be able to remove wire harnesses and reach in to engine bay.
• The rear non-structural bar of the subframe (where motor mount vacuum lines run) should have been a bolt on instead of weld on job by BMW. It is CONSTANTLY in the way of everything happening. If I had a welder and knew how... I'd cut it out and put back in after job completion.
• Remove the transfer case actuator motor to give you enough room to pull back when removing trans (only an issue on diesels, of course, because the passive DEF tank is located there)
• A trans jack would be very helpful, I am buying one before putting the new trans in. We got it out with a floor jack and long adjustable cross support bar that we strapped the trans to. But that was less than ideal, multiple instances of us having to bench press the trans and/or Xfer case. They're heavy.
• You do not need a special tool to turn the engine while removing/installing flywheel bolts. A T12 (I think was the size) works fine on one of the dampener bolts. Just make sure you have it seated well before turning the engine.
• No need for a special tool to hold the flywheel either when removing the 4 bolts. They are not torqued very highly and can be held using the same T12 and ratchet on the dampener as counter rotation.
• Make sure your starter is not frozen/locked in your trans housing like mine was. Hope I didn't damage the teeth or something. Did quite a bit of prying to separate the engine/trans before realizing the starter was not letting the top come loose. The bolts were out, but the starter stayed put.

I'm sure I'm forgetting stuff, but I'll add it as I remember. I blocked it out from my head and took Sunday off mentally. Didn't even clean up the tools/area. Will do that this week in prep for swapping over the transfer case and mechatronics unit.

Here are some pics of the progress.

Smurf massacre. So. Much. Blue.





Tarbo!



See that crossbar in the foreground? That thing can rot in hell!



See that devil starter up there? Cost us at least 45 minutes...



Flywheel. Going to go ahead and pull this because I ordered a rear main seal. And though not leaking, I don't ever plan on dropping this trans again.



Me at 2AM Sunday morning. All 6'8" 250lbs of me were done. I could have slept on that cold garage floor.

[DeafM5]

I had that code after the previous owner messed with the transmission. I just elected to go used junkyard transmission to avoid wasting money and time one go. I bought the X5 this way. I know it had some codes regarding clutches and wouldn't shift out of the park at all. I rebuilt my junkyard valve body and transferred my EGS from old VB to avoid having to re program it.

I sourced an original owner X5 80k miles transmission for 1600 plus 400 in parts from FCP. I have added 25k miles since last year's replacement with no issues! I am currently at 162k right now.

When I first drove the X5 with a working transmission, I was blown away how the transmission shift so smooth and quick for an automatic transmission.

[Happy]

Man down!! Mechanic in distress!!



Wikipedia needs to use this picture to define “Laid Out”.

I hope y’all get it! With the least amount of stress. GL

[crystalworks]

Originally Posted by Happy

Man down!! Mechanic in distress!!

Wikipedia needs to use this picture to define “Laid Out”.

I hope y’all get it! With the least amount of stress. GL

Haha! Thanks Happy. We'll get it. The packaging of the diesels is just crazy tight. Plus as I said, we're working slow. Is what it is.

Originally Posted by DeafM5

I had that code after the previous owner messed with the transmission. I just elected to go used junkyard transmission to avoid wasting money and time one go. I bought the X5 this way. I know it had some codes regarding clutches and wouldn't shift out of the park at all. I rebuilt my junkyard valve body and transferred my EGS from old VB to avoid having to re program it.

I sourced an original owner X5 80k miles transmission for 1600 plus 400 in parts from FCP. I have added 25k miles since last year's replacement with no issues! I am currently at 162k right now.

When I first drove the X5 with a working transmission, I was blown away how the transmission shift so smooth and quick for an automatic transmission.

That's what I'm hoping for DeafM5. Thanks for the inspiration.

[TriX5]

Hey - I usually feel like that before I start work on the X!


Keep at it! On the X5s I find that getting it back together is usually faster coz you know what the right order is and what goes where.