Oh Dear.. There goes the Gearbox!!!
 

Well i have finally been bitten by the Ton club!!!!

just gone throught the 100k (miles) barrier and the gearbox lost all drive, going up hill in traffic!!!

Switch off for 2 mins and start then can drive for 1 min and drive dies (engine runs OK)

Had to get the RAC out to cart it home. None too pleased...

Finally plucked up the courage to drain the oil tonight.
Nice and black and stinks to high heaven. (including the continued stink from the ingrained oil in my hands from a leaky glove!!!!)
Dropped the sump pan to fins a nice pattern of filings stuck to the magnet and in the base of the sump.

Ripped the filter apart for a look and that was clogged with filings too.
NOT GOOD.

Going to be a fun few days now getting the bleeding thing out and inspecting it. Then to see what the damage is and plan the way out.

Oh well here goes nothing...

Sounds daft to say it , but I was really pleased when my box failed at about 50,000 miles, cos I had bmw dealer warrantee on my secondhand x5.
Never cost me a penny and I hopefully have peace of mind for a good few years yet.
Sorry to hear your news though, keep us informed as to what gives.
Regards,
Lez

Thx mate.

Been reading a lot about the GM 5L40E gearbox and there is an awful lot of contradictory advice about refreshing fluid or not.

All i know is once i have done it then it will be changed at least every other year or second oil service.
Also going to get the suppimentary oil cooler for it as i do tow a rather large caravan with it......
(Incedently i was not towing it when it went. Was on my own going to work....awaits derogatory remarks about my waistline:D)

If i remember, i'll take photos along the way, in fact i'd better remember otherwise i will never get it back together correctly otherwise.....


Just got re-aquainted with my 525 TDS touring.. Insured, taxed and back on the road. At least i am not stranded anymore.

Well got gearbox out and completely stripped.

Overall not too bad condition inside apart from:-
Direct and reverse clutch packs showing signs of overheating.
2nd coast clutch cage slightly worn (but serviceable)
Dodgy connector on input speed sensor (mainly cuz i broke the clip!!!)
accumulator 1 spring broken into 4 pieces, may explain the clutches overheating.

Have overhauled the valve pack but awaiting a bush to be made for the broken one as there is a little wear in the casting.
Have overhauled the oil pump and fitted new front end oil seal and torque convertor bush.
Replaced rear gasket and started re-fitting parts into the casing.

Found a superb supplier of all things Auto - www.jpats.co.uk who are not that far from me. They are refurbishing the torque convertor for me and should have it back to me for tuesday.
They have suppled all the friction plates, pistonseals, gasket kit, filter and a secondary oil cooler.

Total cost so far approx £500.
Bit of a saving from £4000 from BMW.....

Will update again soon and poss post some piccies if anyone is interested..

Cheers

awesome , you bet we want pics .

well here are a few pics from the last few days...
It has been an experience, quite challenging but, after all said and done, quite enjoyable.
I love seeing how things are made and this is no exception

As can be seen the primary & Coast clutches got a little warm
and lookig at the fluid i am hardly surprised it failed!!

Seemed to be the worst part within the gearbox apart from the accumulator spring. Photo of that will be later as i forgot to take one!!!

If anyone is as mad as me, of just very, or mildly interested in this sort of thing then you may want to look at the exploded diagram for it:-

http://www.automaticchoice.com/Catalogue/5l40e.pdf

Now you realise just what sort of mind i am harbouring.....
:)

Well an update...

Gearbox now back together apart from the filter and sump pan.
All new clutch packs, pistons and seals done.
Top hat bush fitted to worn section of valve body accumulator (Photos to follow when i have uploaded them from the camera)

Got torque convertor back from repair. (took it in Friday, they had it finished by mid day Saturday but didn't have my phone number to let me know. Very good service in my mind to get it done so quick. Well happy)
Reported that the friction lining had disintegrated and was running metal on metal. Explains a lot. :)

All fluid turned up today (Dexron VI) 12 litres so should be enough (I Hope!!)

Just awaiting the couplings for the secondary transmission fluid cooler as supplier didn't fully understand my request as i had to do it over the phone.

Should get the box back in during the next couple of evenings and top up all fluids. Then hopfully back on the road by the weekend.
Unfortunately then have to tax the thing :yikes:

And another update.. (Must be boring people now????)

Gearbox now rebuilt and transfer box bolted back on.
Not sure whether i should check / change the chain? Will be re-filling with new fluid, and it didn't show signs of distress before so i'll prob leave it.

Fitted secondary oil cooler the other day so tried to plumb it in tonight as only just got the pipe fittings too suit.

All went well until i ran out of hose!!!! then spilt 1/2L of oil over myself!!!!
so left it for today.

Tomorrow will finish off the cooler install then start putting th egearbox back in. :thumbup:

Have some more piccies that i wil post up soon.

Good to see you getting it all back together. Maybe when you do the fluid change on the transfer case you can check the slack in the chain through the drain plug hole with a long skinny screwdriver or something...