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DIY: Do It Yourself
Post here to share or improve your wrench turning skills! All BMW E46 DIY tips, tales, and projects discussed inside. Learn to work on your car and know the right BMW parts you will need!

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Old 01-11-2016, 12:07 PM   #1
Em1l
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Transmission 5hp19 overheating 130C

Hi gays that`s my first post here , and i have a really big issue with my transmission. My car is e46 m54b30 with ZTF 5hp19 tranny. The car was driving and shift perfect , but 2 days ago started to going in limp mode(the gear with (!) sign). I been checking couple times a week the car for errors with my inpa and the temperature before was around 100-105 C degrees. But now is going to 120-130 C which i know is not very good for the transmission. I change the filter and the oil and still doing the same. After the change of the fluid the car is soo smooth , even i can fell when is shifting but when goes after 105 C degrees is showing the (!) gear error sign. I know is a thermostat there and I ordered today but i don`t think is gonna be from the thermostat. Also when i drove the car and when is on 4th gear when i started to stop and transmission is suppose to do downshifting the error light come on. When I accelerating doesn`t have any issues only when I start to stop. The fault which is showing is :


54 Gear Check 4
Error frequency : 1
Logistic counter: 57
Mileage/Km-reading 240660.00 km
Throttle-valve angle 0.00 %
Mean Value - Rear Wheels 304.00 rpm
Output Speed 1088.00 rpm


I dont really know what to do and I read several posts of people in this forum who knows a lot about transmissions.

Last edited by Em1l; 01-11-2016 at 12:09 PM.
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Old 01-11-2016, 01:11 PM   #2
markusmarkus
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It could be the tranny fluid cooler is blocked. It's located in the vicinity of the expansion tank. Also, check the tranny fluid level.
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Old 01-12-2016, 07:16 PM   #3
jjrichar
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To be clear on how the transmission is cooled, it doesn't have it's own thermostat. It gets cooled by the engine coolant. Yes there is a thermostat next to the transmission cooler, but this just regulates coolant flow direction when the engine is warming up so that it warms the transmission faster than it would otherwise do. Once the engine coolant is at operating temperature (about 95 deg C), the transmission fluid is cooled by this, which explains why you normally see the transmission coolant at a bit above 95 deg C (105 in your case).

It could be one of a number of things.

Like markus said, the first thing I would do is check the transmission cooler isn't blocked. Jack up the car, disconnect one of the transmission fluid pipes at the tranny cooler, start the car momentarily (a few seconds max) and check fluid is freely flowing from the hose. Connect again and then disconnect the other and repeat.

If it seems the cooler is not blocked, the next thing I would check is the coolant flow that goes to the tx oil cooler. It may have something to do with the thermostat not directing the flow correctly, and hence not cooling it. If you haven't replaced this part of the cooling system it might be worthwhile doing. It's a component that fails regularly with time.

Also check the transmission temperature wire to see that it's OK. It should be 1000 ohms at 25 deg C. Link below is to a project I did a while back on the transmission. It has links to documents that have the information required to do this.

With regard to the INPA code, this is saying the transmission is slipping in 4th, meaning a clutch somewhere is slipping. This may be due to the temperature, so ensuring the transmission is being cooled correctly is the first thing to do prior to going down other paths.

http://forum.e46fanatics.com/showthread.php?t=928248

Also have a look at this post. I put a photo in it that has the coolant flow direction.
http://forum.e46fanatics.com/showthread.php?t=760515

Last edited by jjrichar; 01-12-2016 at 07:17 PM.
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Old 06-20-2017, 11:41 PM   #4
PancakeBimmer
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Bump.

I have 5hp19 with similar issues, if not worse. During cold starts transmission is shifting properly, but as soon as it reaches higher temperatures everything goes haywire. It feels like slipping, sometimes harsh engagement, other times it is slipping so much that RPM reach 4000 and transmission switches to next gear before even engaging in current gear. Then it goes into limp mode (aka 4th gear) until restart. I have not been paying attention, but only today noticed that it is reaching 250F. My first thought was thermostat, which I assume(d) is like engine thermostat, so I removed it in about 20 pieces... Blew some air though coolant hole sin heat exchanger and it checks out okay.

After removing transmission thermostat all together I took the car for another drive and temperatures kept going up to 250F again. I will try blowing ATF line tomorrow and wanted to ask if anyone knows which hose is inlet and which is outlet for ATF line at the heat exchanger? Thanks
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Old 06-26-2017, 01:58 PM   #5
Doctorboss88
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Does it bang into gear?

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Old 06-27-2017, 07:35 AM   #6
markusmarkus
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Transmission 5hp19 overheating 130C

Hmmm. Since the tranny fluid is cooled by engine coolant (say that 5x!!), the engine coolant passages in the tranny fluid cooler could be partially blocked. If they are partially blocked try running a mixture of vinegar+baking soda through the coolant passages. That'll dissolve the minerals. If that doesn't work try CLR.

How frequently has the coolant been changed? What coolant was used? Was distilled water used? It does matter.

Last edited by markusmarkus; 06-27-2017 at 07:38 AM.
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Old 07-01-2017, 04:41 PM   #7
delgadilloalex
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Your tranny is toast don't waste anymore money on it! i changed the fluid 5 times, cooler itself, cooler lines, and it did not improve. i am able to drive it in manual mode and can prevent the errors. Never switch gears up without throttle. or you will receive the error with slam.
I am swapping tomorrow with manual and my problems should be gone forever. good luck.
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Old 07-04-2017, 11:16 PM   #8
PancakeBimmer
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After replaced burned clutches with used clutches from the spare 5hp19 car drove fine for couple days. Then overheating got worse and worse. Now it slips the same as with before this last rebuild. So again, something is causing transmission to overheat which in turn helps clutches slip and burn. Or something is helping clutches slip and burn thus overheating, which in turn makes the issue even worse. Probably something mechanical in the transmission since valve body was swapped completely and it didn't resolve anything. During rebuild I remember trying to remove D&G drum and it was stuck in there good. Should have though it through at that time.

I am going to rebuild the spare 5hp19 that had broken D&G drum, got new clutch packs as well, plus replacing cracked stator with non cracked one. While at it heat exchanger will be replaced although the current one does not appear to be blocked/clogged.

Anyhow, **** auto transmissions.
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Old 07-11-2017, 12:10 AM   #9
PancakeBimmer
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Torn down the problematic 5hp19 today and basically had to hammer D&G drum out through the output side. So remember D&G drum that was stuck and I didn't bother removing? Well I wish I did because then I would have checked friction plates for rear-most clutch packs. Also I would have probably noticed this.




Very much thanks to the professional that did rebuild this before me
Clutch pack G supposed to have 1 spring, 4 friction plates and 4 steel plates, with end plate and clip.
In this picture there is extra friction plate after another friction plate. After removing friction plates, two that were sandwiched together are damaged. The good one has clutch material missing in places, but the bad one has clutch material completely gone from side that was facing end plate.

D&G drum is chewed up a bit, so that could have helped the issue. Also there was clutch material in some oil passages, however, it wasn't enough to block oil. Some of the clutch packs that go in front of D&G drum are burned like the ones I have replaced before. I don't remember which exactly and by now I am lazy to go check.

Also I should have checked transmission part numbers. The one that came with 330i (it was also replaced and rebuilt) is 009, meanwhile the spare 5hp19 (came out of 530 but was also replaced) is actually 010. The latter one is for 3.0 engines, and the other one is for 2.5 Another plus, whoever replaced transmission on 330 replaced it with transmission or 2.5

010 (for 3.0 engine) has different C clutch cylinder, piston and friction/steel plates. 010 comes with 4 pairs of friction and steel plate, but 009 come with 3 only. Also upper valve body and one piston is different. Everything else is same as
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