Bushings fail. Go through that Gary Ferraro 5HP24. You need to check the clutch packs he goes through the whole thing. The bushings wear out and those shafts get too much play. If you want to tow with that it's best to go through whole thing.
Yeah, if it's apart replace the bushings and seals and look real carefully at all the clutches and steels. An auxiliary trans cooler is probably also a good idea. Gary's videos are great.
I enjoyed this video way to much. Quite cathartic listening to Andrew pull gearboxes apart. You should consider doing some ASMR I hear it's quite lucrative
Your brave taking that apart i personally would give it to professional just for peace of mind and some kind of warranty!!! Good luck 👍 your going to need it
Theres always the fall back plan haha. I think the cost to get these reconditioned at a shop is normally $3-4kaud. So we will see if we can work these out first. I think ill try and get it working by replacing the damaged parts first, then if that works will look in to doing a full reco.
Can't wait to see this back on the road! Make sure to have the torque converter rebuilt while it is out if it has not been already. Those are a common issue with the 4.6iS. Would suck to have to pull the trans back out again. Replacing the rear crank seal and water gasket above it is a good idea while you're in there as well. Numbers 8 and 11 in the diagram. www.realoem.com/bmw/enUS/showparts?id=FB92-EUR-05-2003-E53-BMW-X5_46is&diagId=11_2815
Thank you for actually getting inside these vehicles and showing us how to fix them. These cars cost to much when new to just throw them in the bin when something breaks.
thanks man, i think im going to try and get it working, so it doesnt die when it gets warm if that goes well, i might end up doing a full rebuild/recondition process. We'll see, we'll see.
Andrew your a brave man, hats off buddy that would scare the life out of me but worst case is paying someone else and youve saved money removing it 👍🏴
Yeah thats it. Im gonna try and do it stages. We'll replace these definitely broken bits and see how it runs. Then look in to a full rebuild afterwards.
Seriously, I would be a great younger brother. (adoption reference lol) I can be there in about 30hours of flying or so! This is so cool!!! Such a great buy! Would love to be helping out mate if I didn't live on the other side of the planet. Looks like so much fun, what is better than buying a cheap beemer and fixing it up??
You got it dude. Gets stressful at times, but when you do actually end up with a fixed car its a bloody awesome feeling. Maybe this corona madness will be over soon little bro :P
I would love to get my hands on a gearbox from a scrap car to take apart and see what goes on inside, but to do it on a car I own... Well hats off to you! So many parts!!
Great Video! Its like watching a 5 year old taking a clock apart to figure out how it works!! LOL kidding. Great Job guys!! We just pulled the transmission out of our N54 335xi, transfer case makes the transmission hard to manage but we left it on. Rear main seal popped due to bad PCV and 19psi boost!!
Good work. Nice learning as you learn. Have no idea how you’ll find those parts? Will you find them locally or from overseas? Good luck! Hope it’s a relatively easy fix👍🏻
Found the drum in Germany and the bearing in the states for reasonable prices. But have also sent an email to ZF australia, see if they will sell them to me, or at least put me on to a reseller to get them sooner.
jokes aside, the short ones bolt the oil pump to the bell housing. The longer ones bolt the whole lot to the main gearbox housing. However, normally all bolts are the same colour. They are made of the same material they should corrode the same. Figured it might have been opened before.
Hi Andrew. Looking at past auctions on these cars on Grays and they've been going incredibly cheap over the last 4 years. The 4.6is engine would be a great upgrade to your brother's TU 540i, essentially making it an Alpina B10 spec car and probably in the mid 5s 0-60. Do you think the upgraded ZF box in the X5 could be adapted to the E39? Keep up the good content.
A lot of people were buying the 4.6l for the e39 540 swaps but the supply has dried up it would seem. The motors are bloody hard to get now and worth a pretty penny. If you get bored there’s quite a few documented swaps in the us and with some decent headers and tune they roll close to e39 m5 power. As for the box going in the e39. I’m really not sure that said the lesser weight on the e39 would probably help reduce the load in the trans verse the heavy x5. The supercharged 540s would make decent power and those autos seem ok. Have you got a link to some of the ones you saw on grays? Keen to see some price history over the last 12 months.
Highly recommended you get the overhaul kit and replace all the clutch pack & plate, seals since you have almost takes it all apart. Inspect the clutch pack and there were almost in every drums and sometimes it get worn out till bare metal which is bad. If you want cheap overhaul kit, get it at www.shenghaiautoparts.com/. The overhaul kit will include gaskets, seals(alot), clutch packs & plates (the heaviest) and some overhaul kit for the valvebody(need to be extra careful when doing this). I've done overhaul twice on 5hp19 trans and currently in progress overhaul 4hp22. At first I have no confidence much doing it but after doing much research, I manage to successfully complete it. Also you need a compress tool for inorder to remove the pistons of every drums (change the seals).
At the 7 minute point is where I'd be getting scared, how to remember the re assembly of everything 😂 Also wanted to know how you're so good at sourcing parts? Sometimes in England it's hard enough just to get a bloody air filter for your car depending on what you're driving!
Try AUTODOC, they have an app for android not sure on ios. Bad side is delivery times can be ~8 days or more as based in Germany I think. But they have a good range of parts certainly for my e92 N55 in the UK and they always have discounts running.
Hey John, Dave and myself used to run a rather large parts business, right when the industry was switching over to online catalogues and sales. We have spent more hours than we would care to remember creating fitment data for parts. So normally know where to look when it comes to parts.
For zf parts you can easily find their repairinstructions online as you can find parts catalages, there is a repairgroup in Facebook etc...finding needed parts is not the hassle...
You've gone this far, might as well throw a rebuild kit at it. Often the rebuild kits $$$ wise arent that bad, most of the cost is labour (which for you, is "free") - unless.....can you ZF6 swap it?
I initially saw the rebuild kits and thought jesus, thats cheap. But turns out, even using china spec parts, to really rebuild everything, valve body, bushes, clutches, orings and other seals. It's gonna be the best part of a grand for the parts. But i'm still keen to do it if we are gonna start thrashing on this thing. Im going to replace these broken bits i found here, re-assemble and make sure i at least get an improvement. Then do a full rebuild. I know it seems like extra work, but i dont mind pulling it out again. I dont really want to spend the extra $1000 straight up incase i mess something up. I figure the least i pull apart now the better, while i keep learning how to work on these things. If i put it back in and its no different, that means i have made a mistake putting this back together and she'll off to a shop to do it properly.
@@ZeroTo60Tube thanks for quick response. Im gonna search some.. I have a problem now, and it is when the gearbox heat up , I have terrible gear change when breaking, 2. To 1…. I have feel that she wants to get some ice cream 🍦 and come back 🤣🤣 I changed Torque Converter but it’s not better, and that happens just when I drive for long time in city… I think some of O-Rings failed… What about big cooler for gearbox oil? You made an upgrade It makes anything better?
Well interestingly, i found a photo of a new bearing. It had 34 rollers. Which is how many i fished out. However when i sat them in the bearing, with the way the shells have warn, it looks like it was missing a few. But i think its just the shells wearings. As long as the new one has 34 rollers when it arrives, i think ill just send it and see how it goes. If i can get it working without entering trans failsafe, i might look at putting a reco kit through it with new clutches.
@@ZeroTo60TubeCool cool. You may have gotten lucky this time mate. Looks likes a relatively straight forward repair. Fingers crossed. The big issue I guess is if you don't rip her right down you may miss something else. Are there other common points of failure further in? Anyway makes for good content. Awesome stuff mate.
@@joshbrennan8545 Yes, well the valve body is definitely another failure point. Dont get me wrong the correct thing to do is to keep stripping it down. But the issue with no drive in 1st-4th when warm should be in these components i have pulled apart here. When cold it does shift quite nicely, so hopefully valve body and solenoids are ok..... we'll know soon.
Bloody oath.... keen as for a run someday. Euroday? I love all euros, just seem to understand how to fix BMW problems......which is why i seem to be surrounded by them.
hi andrew master rebuild kit for a zf5hp24 and 24a on ebay out of china $550 AUD seller is transpeed transmission parts but you still need to buy the bearing race and drum
Thanks man, i have been eyeing some kits from china. I think if replacing these parts gets it to work without failsafe, we'll pull it out and do a proper recondition, all the other seals and clutches etc.
Hey great video lads. I’ve been having some problems with my 335i. Would y’all happen to know what would cause the Hpfp to shut off completely under minimal load? I thought my hpfp was going bad so I replaced it and no luck. My lpfp is fine too. Only code is fuel pressure plausibility, car jerks really bad.
If you can log the car to see what the HPFP sensor is seeing that is where i would start. If the log looks normal it will get tricky. But the if the log is erratic, it could be something as simple as the HPFP sensor.
@@ZeroTo60Tube The rail pressure sensor? I took a log and it is very erratic going from 1800psi down to 500 in a second back and forth until the hpfp crashes leaving the rail pressure at 85~ psi which is what the low pressure pump is putting out. While doing so the car jerks violently as you would imagine. If you could take a look at the log it would be awesome datazap.me/u/angelz0418/crap?log=0&data=11-20-21
There's another 2 clutch drum assemblies and also the valve body. Im going see if changing these broken parts fixes it and really just to make sure i can put one of these back together. Then will look at doing a full rebuild.
This link might be very helpful if you haven't come across it already; complete pdf with each and every part labeled for your specific transmission. aftermarket.zf.com › pdf-files PDF Web results ZF 5HP24 Automatic Transmission - Spare Parts Catalog Table of ... - ZF Aftermarket
Unfortunately I barely passed high school. But that’s it as far as education goes. Not a mechanic been in management positions most of work life. Just a huge passion for cars, the engineering behind them and learning how they work.
i found this online, which i think is accurate. "In case it’s of interest, when the ZF 5HP24 transmission started production in 1996 it was quoted as having a maximum input torque capacity of 420Nm. When it was specified by BMW against the 440Nm M62 engine it’s torque rating, as luck would have it, suddenly became 440Nm (hence it was designated the A5S440Z). The 4.6is engine produces (at least) 480Nm peak torque. It could be argued, therefore, that the old transmission is being somewhat ‘overstretched’ in this application. To beef it up, ZF fitted the 4.6is transmission with a larger L51-type 12” torque converter (and therefore a bigger bellhousing). The D brake - used in 3rd & 5th gears - had an extra clutch plate in it (5 plates instead of 4) and the upper valve block was modified to accommodate revised designs for the B & E clutch valves. To differentiate between them the 4.4i E53 transmission is an ‘029’ model and the 4.6is is an ‘034’ model."
if I’m correct the box on 3.0i is also 5hp24 with the 420 rating, but the difference should be only with the bellhousing compared to the 4.4. edit: 3.0i has 300Nm of torque, yet at the last oil change I was said the box on mine has worn reverse clutches. nothing is eternal, eh? 322k kms on it
Yeah, well i was hoping it was low fluid first off haha. I think this appears to be one of the most common failures on the ZF5HP24 boxes. Will be interesting to see if we can fix it.
Big props to you for having a go on your first transmission. All sorts of magic and witchcraft go on inside there.
Always been fascinated by them, its good to finally get to see inside one.
Bushings fail. Go through that Gary Ferraro 5HP24. You need to check the clutch packs he goes through the whole thing. The bushings wear out and those shafts get too much play. If you want to tow with that it's best to go through whole thing.
Yeah, if it's apart replace the bushings and seals and look real carefully at all the clutches and steels. An auxiliary trans cooler is probably also a good idea. Gary's videos are great.
I enjoyed this video way to much. Quite cathartic listening to Andrew pull gearboxes apart. You should consider doing some ASMR I hear it's quite lucrative
Noted!
This vid literally put me to sleep but in a good relaxing way
anyone else notice the wacky glitch at 0:44 ?
Unfortunately, no one can be told what The Matrix is.
Your brave taking that apart i personally would give it to professional just for peace of mind and some kind of warranty!!! Good luck 👍 your going to need it
Theres always the fall back plan haha. I think the cost to get these reconditioned at a shop is normally $3-4kaud. So we will see if we can work these out first. I think ill try and get it working by replacing the damaged parts first, then if that works will look in to doing a full reco.
Can't wait to see this back on the road! Make sure to have the torque converter rebuilt while it is out if it has not been already. Those are a common issue with the 4.6iS. Would suck to have to pull the trans back out again. Replacing the rear crank seal and water gasket above it is a good idea while you're in there as well. Numbers 8 and 11 in the diagram.
www.realoem.com/bmw/enUS/showparts?id=FB92-EUR-05-2003-E53-BMW-X5_46is&diagId=11_2815
Thank you for actually getting inside these vehicles and showing us how to fix them. These cars cost to much when new to just throw them in the bin when something breaks.
Really awesome of you to tackle this yourself! I will definitely be watching you fixing it, good luck!
thanks man, i think im going to try and get it working, so it doesnt die when it gets warm if that goes well, i might end up doing a full rebuild/recondition process. We'll see, we'll see.
Andrew your a brave man, hats off buddy that would scare the life out of me but worst case is paying someone else and youve saved money removing it 👍🏴
Yeah thats it. Im gonna try and do it stages. We'll replace these definitely broken bits and see how it runs. Then look in to a full rebuild afterwards.
Seriously, I would be a great younger brother. (adoption reference lol) I can be there in about 30hours of flying or so!
This is so cool!!! Such a great buy! Would love to be helping out mate if I didn't live on the other side of the planet. Looks like so much fun, what is better than buying a cheap beemer and fixing it up??
You got it dude. Gets stressful at times, but when you do actually end up with a fixed car its a bloody awesome feeling. Maybe this corona madness will be over soon little bro :P
I would love to get my hands on a gearbox from a scrap car to take apart and see what goes on inside, but to do it on a car I own... Well hats off to you! So many parts!!
Well we already knew the gearbox was toast. Let's see if we can improve it a little.
Get yourself some white spirit for cleaning before assembly, leaves no residue 😎 good luck with the parts
Thanks for the tip!
Great Video! Its like watching a 5 year old taking a clock apart to figure out how it works!! LOL kidding. Great Job guys!! We just pulled the transmission out of our N54 335xi, transfer case makes the transmission hard to manage but we left it on. Rear main seal popped due to bad PCV and 19psi boost!!
Ahhhh damn, thats something you wouldnt expect but makes sense. Let us know how the repair goes.
Better find those last 2-3 rollers. It's like the worlds worst Where's Waldo puzzle. Been there done that.
Good work. Nice learning as you learn. Have no idea how you’ll find those parts? Will you find them locally or from overseas? Good luck! Hope it’s a relatively easy fix👍🏻
Found the drum in Germany and the bearing in the states for reasonable prices. But have also sent an email to ZF australia, see if they will sell them to me, or at least put me on to a reseller to get them sooner.
It's like a big jigsaw puzzle 👍
The short bolts are there for a reason to go into shorter holes in the bell housing ;)
haha, no way... that makes so much sense :P
@@ZeroTo60Tube that’s why they are a different “colour” I suspected , that you said it looks like someone before put different bolts back in ;)
jokes aside, the short ones bolt the oil pump to the bell housing. The longer ones bolt the whole lot to the main gearbox housing. However, normally all bolts are the same colour. They are made of the same material they should corrode the same. Figured it might have been opened before.
any update on how it all went back together?
Hi Andrew. Looking at past auctions on these cars on Grays and they've been going incredibly cheap over the last 4 years. The 4.6is engine would be a great upgrade to your brother's TU 540i, essentially making it an Alpina B10 spec car and probably in the mid 5s 0-60. Do you think the upgraded ZF box in the X5 could be adapted to the E39?
Keep up the good content.
A lot of people were buying the 4.6l for the e39 540 swaps but the supply has dried up it would seem. The motors are bloody hard to get now and worth a pretty penny. If you get bored there’s quite a few documented swaps in the us and with some decent headers and tune they roll close to e39 m5 power.
As for the box going in the e39. I’m really not sure that said the lesser weight on the e39 would probably help reduce the load in the trans verse the heavy x5. The supercharged 540s would make decent power and those autos seem ok.
Have you got a link to some of the ones you saw on grays? Keen to see some price history over the last 12 months.
I can see a win in the distance!
Fingers crossed, really looking forward to having a proper drive in this rig.
Highly recommended you get the overhaul kit and replace all the clutch pack & plate, seals since you have almost takes it all apart. Inspect the clutch pack and there were almost in every drums and sometimes it get worn out till bare metal which is bad. If you want cheap overhaul kit, get it at www.shenghaiautoparts.com/. The overhaul kit will include gaskets, seals(alot), clutch packs & plates (the heaviest) and some overhaul kit for the valvebody(need to be extra careful when doing this). I've done overhaul twice on 5hp19 trans and currently in progress overhaul 4hp22. At first I have no confidence much doing it but after doing much research, I manage to successfully complete it. Also you need a compress tool for inorder to remove the pistons of every drums (change the seals).
Hard parts
what happened to the two missing rollers???
At the 7 minute point is where I'd be getting scared, how to remember the re assembly of everything 😂
Also wanted to know how you're so good at sourcing parts? Sometimes in England it's hard enough just to get a bloody air filter for your car depending on what you're driving!
Try AUTODOC, they have an app for android not sure on ios. Bad side is delivery times can be ~8 days or more as based in Germany I think. But they have a good range of parts certainly for my e92 N55 in the UK and they always have discounts running.
Hey John, Dave and myself used to run a rather large parts business, right when the industry was switching over to online catalogues and sales. We have spent more hours than we would care to remember creating fitment data for parts. So normally know where to look when it comes to parts.
Now it makes sense！haha
For zf parts you can easily find their repairinstructions online as you can find parts catalages, there is a repairgroup in Facebook etc...finding needed parts is not the hassle...
You've gone this far, might as well throw a rebuild kit at it. Often the rebuild kits $$$ wise arent that bad, most of the cost is labour (which for you, is "free") - unless.....can you ZF6 swap it?
I initially saw the rebuild kits and thought jesus, thats cheap. But turns out, even using china spec parts, to really rebuild everything, valve body, bushes, clutches, orings and other seals. It's gonna be the best part of a grand for the parts. But i'm still keen to do it if we are gonna start thrashing on this thing. Im going to replace these broken bits i found here, re-assemble and make sure i at least get an improvement. Then do a full rebuild. I know it seems like extra work, but i dont mind pulling it out again. I dont really want to spend the extra $1000 straight up incase i mess something up. I figure the least i pull apart now the better, while i keep learning how to work on these things. If i put it back in and its no different, that means i have made a mistake putting this back together and she'll off to a shop to do it properly.
Hey, can you send me some link of Full rebuild kit for it?
Because here in Germany they dont sell to private persons these parts 🤷🏻♂️
I never got a full rebuild kit. but i have seen them on ebay.
@@ZeroTo60Tube thanks for quick response. Im gonna search some..
I have a problem now, and it is when the gearbox heat up , I have terrible gear change when breaking, 2. To 1…. I have feel that she wants to get some ice cream 🍦 and come back 🤣🤣
I changed Torque Converter but it’s not better, and that happens just when I drive for long time in city… I think some of O-Rings failed…
What about big cooler for gearbox oil?
You made an upgrade
It makes anything better?
Love the vids.
Thanks dude.
Good luck
Good video, keep it up
great video a always
Thanks dude.
Nice work mate! Looks like you've solved it. Did you find the other rollers?
Well interestingly, i found a photo of a new bearing. It had 34 rollers. Which is how many i fished out. However when i sat them in the bearing, with the way the shells have warn, it looks like it was missing a few. But i think its just the shells wearings. As long as the new one has 34 rollers when it arrives, i think ill just send it and see how it goes. If i can get it working without entering trans failsafe, i might look at putting a reco kit through it with new clutches.
@@ZeroTo60TubeCool cool. You may have gotten lucky this time mate. Looks likes a relatively straight forward repair. Fingers crossed. The big issue I guess is if you don't rip her right down you may miss something else. Are there other common points of failure further in? Anyway makes for good content. Awesome stuff mate.
@@ZeroTo60TubeAlso, don't hate me but I'm an Audi guy, in Brisbane also. Will have the have a drag one day soon. Hey at least it's German.
@@joshbrennan8545 Yes, well the valve body is definitely another failure point. Dont get me wrong the correct thing to do is to keep stripping it down. But the issue with no drive in 1st-4th when warm should be in these components i have pulled apart here. When cold it does shift quite nicely, so hopefully valve body and solenoids are ok..... we'll know soon.
Bloody oath.... keen as for a run someday. Euroday? I love all euros, just seem to understand how to fix BMW problems......which is why i seem to be surrounded by them.
hi andrew master rebuild kit for a zf5hp24 and 24a on ebay out of china $550 AUD seller is transpeed transmission parts but you still need to buy the bearing race and drum
Thanks man, i have been eyeing some kits from china. I think if replacing these parts gets it to work without failsafe, we'll pull it out and do a proper recondition, all the other seals and clutches etc.
Hey great video lads. I’ve been having some problems with my 335i. Would y’all happen to know what would cause the Hpfp to shut off completely under minimal load? I thought my hpfp was going bad so I replaced it and no luck. My lpfp is fine too. Only code is fuel pressure plausibility, car jerks really bad.
If you can log the car to see what the HPFP sensor is seeing that is where i would start. If the log looks normal it will get tricky. But the if the log is erratic, it could be something as simple as the HPFP sensor.
@@ZeroTo60Tube The rail pressure sensor? I took a log and it is very erratic going from 1800psi down to 500 in a second back and forth until the hpfp crashes leaving the rail pressure at 85~ psi which is what the low pressure pump is putting out. While doing so the car jerks violently as you would imagine. If you could take a look at the log it would be awesome
datazap.me/u/angelz0418/crap?log=0&data=11-20-21
Nice video! What else is left in the transmission? Can we get a N54 mug I want one. :)
There's another 2 clutch drum assemblies and also the valve body. Im going see if changing these broken parts fixes it and really just to make sure i can put one of these back together. Then will look at doing a full rebuild.
Ah. I would be very tempted to take it apart searching for those bearing pieces - might not be the best idea though.
I would get an original ZF kit and not chance it with some "dickass" components👌
This link might be very helpful if you haven't come across it already; complete pdf with each and every part labeled for your specific transmission.
aftermarket.zf.com › pdf-files PDF Web results ZF 5HP24 Automatic Transmission - Spare Parts Catalog Table of ... - ZF Aftermarket
Are you a mechanic? If not what's your educational background? if you don't mind me asking. You seem very intelligent.
I assure you it's all a ruse.
Unfortunately I barely passed high school. But that’s it as far as education goes. Not a mechanic been in management positions most of work life. Just a huge passion for cars, the engineering behind them and learning how they work.
Have you called few wreckers for a used box?
Unfortunately can’t find a 4.6 box. Only the 4.4.
@@ZeroTo60Tube some internals might be the same but really nowhere to confirm
i found this online, which i think is accurate.
"In case it’s of interest, when the ZF 5HP24 transmission started production in 1996 it was quoted as having a maximum input torque capacity of 420Nm.
When it was specified by BMW against the 440Nm M62 engine it’s torque rating, as luck would have it, suddenly became 440Nm (hence it was designated the A5S440Z).
The 4.6is engine produces (at least) 480Nm peak torque.
It could be argued, therefore, that the old transmission is being somewhat ‘overstretched’ in this application.
To beef it up, ZF fitted the 4.6is transmission with a larger L51-type 12” torque converter (and therefore a bigger bellhousing). The D brake - used in 3rd & 5th gears - had an extra clutch plate in it (5 plates instead of 4) and the upper valve block was modified to accommodate revised designs for the B & E clutch valves.
To differentiate between them the 4.4i E53 transmission is an ‘029’ model and the 4.6is is an ‘034’ model."
if I’m correct the box on 3.0i is also 5hp24 with the 420 rating, but the difference should be only with the bellhousing compared to the 4.4.
edit: 3.0i has 300Nm of torque, yet at the last oil change I was said the box on mine has worn reverse clutches. nothing is eternal, eh? 322k kms on it
@@ZeroTo60Tube www.thectsc.com/catalog/5-speed-parts-110.html
6:51
Umm...the M5 is back ????
It is!!!! Update coming in a few days, we still havent had a chance to touch it and its still all in bits after the paint.
👍
I was hoping it'd just be dead solenoids :(
Yeah, well i was hoping it was low fluid first off haha. I think this appears to be one of the most common failures on the ZF5HP24 boxes. Will be interesting to see if we can fix it.
🤔🤞👍👍