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

[SF2000x5]

Just anecdotal evidence: the transmission shifts smoother every time I replace the fluid. Ive drained every 10k miles for the last 30k or so.

[crystalworks]

Originally Posted by SF2000x5

Just anecdotal evidence: the transmission shifts smoother every time I replace the fluid. Ive drained every 10k miles for the last 30k or so.

Out of curiosity, do you do a re-learn of the adaptations every fluid drain?

Work continues. We spent all of Saturday on it. A good 16 hours... I know, I know, we're working slow as molasses creeps. Well, we're doing it all on our backs, and there's a bunch of "while we're in there" going on too. So that's my excuse. I'm slow, I've made peace with it. Had to make a couple of tool and fluid runs too, so time management could have been better.

On Saturday we:

• R&R'd flywheel
• Installed new rear main seal
• Replaced worn (completely torn) transfer case mount
• Swapped Xfer case from old trans to new transmission.
• Installed new rear driveshaft flex disk/guibo
• Installed new transmission into the X5 (making sure the converter aligns with the flywheel, AND stays engaged with the pump is fun on your back )
• Installed starter onto trans bell housing

Some pics:



Isn't that supposed to be attached in the middle somewhere?



I was in a hurry when I bought this mount so ended up getting a "Power Torque" mount from O'Reillys. LoL, I have no experience with Power Torque so went ahead and dumped a bunch of gasket maker into it just for good "feels." No matter how bad the pookie filled Power Torque bushing is, it's better than the torn one that was in there.



The bearing press took I bought at Harbor Freight didn't have the exact right cup size for the bushing so a roll of Gorilla Tape filled in nicely. Worked like a charm and took about 10 seconds to install.



Old transmission after pulling the mechatronics/valve body out.



Here's a shot of the back of the motor after pulling the flywheel and old RMS. Took the shot for the info on the back of the block for S's and G's as I don't ever plan on being able to see that sticker so clearly again.

Now that everything is "installation is the reverse of removal" hopefully things will go a little quicker. Going to loosen the steering rack and really drop the subframe this time though so that the DPF and engine mount arm goes in easier. It was not fun wiggling those out.

[crystalworks]

Nothing big to report. Been busy ordering parts for "while I'm in there" work. Waiting for a pair of pressure converters, 30' of 3.5x2.0mm vacuum line (all black, I know, won't look factory... I'm cheap... cheapish anyway), a fuel filter, and waiting for the DPF to come back from a diesel truck shop for a cleaning. I don't want to be back under the truck for awhile after all this... if I can help it.

In the meantime today I managed to get the torque wrench on all of the bell housing bolts, including the starter bolts. Fun times were had. Rearranged the jacks around supporting the drivetrain for more room to work up front. Went to torque the flywheel bolts and realized I don't have a way to hold the crank. Sooooo, waiting on a tool for that now too.

Not sure if anyone is following along or if I am talking to myself. But, I've heard writing your thoughts down is good for the psyche. We'll see if that holds true. The pitcher of margaritas I had earlier didn't hurt.

[jcarpfishman]

Originally Posted by crystalworks

Not sure if anyone is following along or if I am talking to myself. But, I've heard writing your thoughts down is good for the psyche. We'll see if that holds true. The pitcher of margaritas I had earlier didn't hurt.

I thoroughly enjoy this kind of stuff, especially if it aligns with tasks I'm about to dive into. Keep the updates and pictures coming!

I'm thinking that I will be rebuilding my transfer case at a minimum, but I'm debating sending my tranny off to be rebuilt as I suspect the damage is already done to the planetary gear bushings causing fluid pressure loss in various circuits.

From the research I was doing, it seems that there are common parts in the ATC700 that go out as well (output shaft bearing, piston & what appears to be a follower/activation arm with a roller bearing on the end). I noticed that some of my shifting issues got better after disconnecting the actuator on the transfer case leaving me stuck in RWD all the time. Specifically, the weird hunting shifts in the middle of intersections have mostly gone away since pulling the transfer case out of the equation. I suspect that something is binding up in it putting a sudden unexpected load on the tranny while going through low speed turns.

Before you fully re-assemble, have you popped apart your transfer case actuator to ensure the plastic gear is not hosed?

[crystalworks]

Originally Posted by jcarpfishman

I thoroughly enjoy this kind of stuff, especially if it aligns with tasks I'm about to dive into. Keep the updates and pictures coming!

Will do. I should be taking more pics, but it's hard to remember when under the truck to crawl out and grab the phone.

Originally Posted by jcarpfishman

I'm thinking that I will be rebuilding my transfer case at a minimum, but I'm debating sending my tranny off to be rebuilt as I suspect the damage is already done to the planetary gear bushings causing fluid pressure loss in various circuits.

From the research I was doing, it seems that there are common parts in the ATC700 that go out as well (output shaft bearing, piston & what appears to be a follower/activation arm with a roller bearing on the end). I noticed that some of my shifting issues got better after disconnecting the actuator on the transfer case leaving me stuck in RWD all the time. Specifically, the weird hunting shifts in the middle of intersections have mostly gone away since pulling the transfer case out of the equation. I suspect that something is binding up in it putting a sudden unexpected load on the tranny while going through low speed turns.

Before you fully re-assemble, have you popped apart your transfer case actuator to ensure the plastic gear is not hosed?

I have the actuator off the Xfer case right now so I'll give it a gander. Good idea, one more part to order. LoL. Or I guess I could flip the gear.

RE your problem. Have you scanned the truck to see if either the ATC700 or the EGS are reporting anything? I find the E70's gearbox is just programmed to get to high gear as quickly as possible. As such it feels awkward sometimes during low speed acceleration. The wife always complained about it. There might be updated EGS software to help with it but I haven't looked into it.

Got my DPF back. One day turnaround. They said it's one of the cleanest ones they've ever seen regardless of mileage and that the truck must be a well taken care of example. This x5 is at 166,000 miles and 30,000 under our ownership. Told him previous owner was a dealer who would drive it between Texas and Louisiana so my guess is that the regenerations have always been regular as we don't do any regular short trips in it either. He agreed that sounded right.

Usually DPFs are flow tested but for the Euro ones they get they aren't setup for air flow testing so instead weigh each unit before and after. They usually do commercial semis and fleets as you can imagine. Actually took me 5 calls before I could find someone to clean this thing. Sheet says they pulled out 56g of soot/ash. More importantly for me as this was done as preventative maintenance is that the DPF got a clean bill of health and will not EVER need to come out again in my ownership. At $400+tax this is cheap compared to a new $2400+tax unit.





I had to separate the SCR injection tube from the DPF flex pipe and all the sensors before giving the DPF over for cleaning. Posting this picture to show that we had bent the 2 EGT sensors up a bit during the removal process. I ohmed them and both are similar at ~14.6K ohms so I bent them back carefully/slowly and ohmed them again. Still reading where they were before and both are close so hopefully I didn't bork those up. @ $65/ea it would just add to the cost... which I will tally up fully later.

[crystalworks]

Still plugging away. On Tuesday I got the flywheel bolts torqued up. Also got the DPF back in the truck and loosely mounted (still have to install engine arm and mount so need play). That was a big accomplishment. Much easier than getting it out. I unbolted the steering rack and let it hover so I was able to lower the subframe another inch or so. That made a HUGE difference and gave me necessary clearance. Needed to employ the wife for a minute or two on the 4' pry bar while I maneuvered the DPF in. But was much easier going in than coming out.

Some notes:

• Crank holder/turning tool requires the removal of the fan shroud for clearance.
• Be sure to loosely install each flywheel bolt before torquing. I had to re-loosen 3 of them when the 4th (of course) would not quite line up with the torque converter.
• Easy to locktite and torque the flywheel bolts to 42ft lbs using the crank tool. Without it I was turning the motor before reaching torque spec.
• Unbolt the 4 nuts/bolts on the steering rack to allow the subframe more droop. Provides much needed clearance for the DPF filter to be reinstalled.
• Getting the 2 vacuum lines on the DPF SUCKS. I should have sprayed the nipples with soapy water before installing, but then they would have been slippery... so. Wanted to order new lines for those but they were on back order.

A couple of shots of the new RHS motor mount versus a new mount. Had not completely failed, but definitely had some droop to it.

[itscoo2pyopants]

nice work!

doing similar work to my e46. still putting it back together, but wasn't as bad as I thought.

[crystalworks]

Originally Posted by itscoo2pyopants

nice work!

doing similar work to my e46. still putting it back together, but wasn't as bad as I thought.

I imagine anything would seem "not as bad" as this diesel. LOL. I feel like I could drop a trans in a gas powered BMW in a day easy after fiddling with this DPF, EGR Cooler, and SCR stuff.

Got some more work done on Monday. Put in about 3 hours doing various things.

Finished the fuel filter install. That was an ordeal that I had started on Saturday because the 5" rubber line that U-turns after the filter was cracked and started leaking after I had disturbed it. "No problem" I thought. I'll run to O'Reilly and pick up a small piece of fuel line. Nope, nothing will make that radius without kinking. Ugh, guess I'll have to pick up that piece from BMW. $85 later I had it as they do not sell the rubber portion separately. You have to buy the whole plastic piece too.

Also got the motor mount arm reinstalled and both new motor mounts in place. The engine can now rest on its own mounts for the first time in a couple of months. :party0030: Haven't torqued anything yet as I anticipate having to move things around a bit while trying to get the EGR cooler and sensors back in place on the DPF. That should be fun...

• Fuel filter and line installed
• RS Engine mount arm installed
• Both engine mounts installed loosely to engine arms

I think Continental custom makes that small fuel line in that shape using a form. I could not get anything to make that radius.





This shows condition of LS motor mount. Not failed, but like the other side, has some obvious droop to it.



This is the steering shaft that you have to be wary of when lowering the subframe. You don't want to damage the seal that that shaft rides in or you will have a power steering fluid leak. Best to undo the steering rack (4 hard to reach nuts/bolts) so you can limit the amount the rack drops.







You can see all my pink torque markings on the fasteners that have been done. Still need to torque the arm down, the one bolt behind the DPF is an absolute PITA to get to. Should be fun trying to get a torque wrench on that.

[Happy]

Dang.... Crystal, you’re a master tech!

[crystalworks]

Originally Posted by Happy

Dang.... Crystal, you’re a master tech!

YouTube Certifications have been earned! Finally hung the banner my wife gave me... so you it's official now.

Thanks Happy. I'm far from a master tech, one of those would have had this job done in 2 weekends even on their back I'm sure.

Wife agreed our next place must have space for a lift. Or we are going to do a garage addition here to add one. I'm turning 40 next year and Murtaugh's famous quote is becoming more and more applicable personally.