Transmission Replacement???

[jeff540i]

Well, it finally happened. After 165,000 miles, my 1994 540i's 5spd ZF automatic transmission has started to fail. I received the dreaded "TRANS PROG" message and the car settled into 3rd gear "safe mode." It hasn't given me the error since, and is using all five gears, but it is not performing like it should.

I took it to a highly regarded, independent BMW mechanic. He told me the Speed Sensor was shot and the torque converter is not good. His recommendation is to replace with a certified rebuilt transmission from ZF. He said it would come with a 2yr warranty and make the car run good as gold - which it ought to for a quote of $4,600: $4,000 (parts) + $600 (labor).

Car's in otherwise good shape. Recent maintenance includes new brake pads, tires, shocks, a/c compressor, engine speed sensor, fuel pump, LKM, electric fan clutch, exhaust hangers, and O2 sensors. It's had both the Tech I and Tech II services and got the Alusil engine at 50,000 miles.

Anyway - question to the forum: what would you guys recommend? Is the price quote reasonable? Would you try fixing the tranny yourself?

Only other idea is to sell "as-is." I'd part with it for less than the $4,600 quote.

Thanks,

Jeff

[bmwpower]

If it were me, and I'm sure it will be someday, I would replace it myself with a rebuild unit from Zf or BMW or other reputable german shop (NOT Aamaco). If the cost was way too crazy - I would classify $4 as crazy - I would consider a 5 spd. conversion.

There's always the possibility of getting a used unit from a low mileage car. That might be a better option. If it lasts another 165k, it's probably worth it.

[jeff540i]

If it were me, and I'm sure it will be someday, I would replace it myself with a rebuild unit from Zf or BMW or other reputable german shop (NOT Aamaco). If the cost was way too crazy - I would classify $4 as crazy - I would consider a 5 spd. conversion.

There's always the possibility of getting a used unit from a low mileage car. That might be a better option. If it lasts another 165k, it's probably worth it.
Thanks for the input - hopefully you'll have many miles before your in this predicament ;-)

Any idea what a rebuild direct from ZF costs? I suspect the $4k includes a nice mark-up.

A guy from a junk yard quoted me $1,500 for a used one with 56,000 miles on it, but I wonder about the quality.

If I can get this thing running for under $3,000 I'll keep it forever. Manual conversion would be awesome - I've kicked myself numerous times for not buying the 6spd years ago.

[MBXB]

Contact @ ZF:

Kirt Koeller
Autosportsunlimited.com
work (616) 748-5735
other (800) 624-3876
Zeeland MI

Phone is best way to contact.




Thanks for the input - hopefully you'll have many miles before your in this predicament ;-)

Any idea what a rebuild direct from ZF costs? I suspect the $4k includes a nice mark-up.

A guy from a junk yard quoted me $1,500 for a used one with 56,000 miles on it, but I wonder about the quality.

If I can get this thing running for under $3,000 I'll keep it forever. Manual conversion would be awesome - I've kicked myself numerous times for not buying the 6spd years ago.

[bmwpower]

Thanks for the input - hopefully you'll have many miles before your in this predicament ;-)

Any idea what a rebuild direct from ZF costs? I suspect the $4k includes a nice mark-up.

A guy from a junk yard quoted me $1,500 for a used one with 56,000 miles on it, but I wonder about the quality.

If I can get this thing running for under $3,000 I'll keep it forever. Manual conversion would be awesome - I've kicked myself numerous times for not buying the 6spd years ago.

I've heard they cost around $1500-2000 but that was a couple of years ago, however the info was from a knowledgeable BMW E34 enthusiast. Call your local BMW dealer and see what it would cost from them.

Where are you located?

[Chris'91'525i]

Contact @ ZF:

Kirt Koeller
Autosportsunlimited.com
work (616) 748-5735
other (800) 624-3876
Zeeland MI

Phone is best way to contact.

I would call ZF.
Most shops mark up parts by 100%.
Also be aware the supplier usually wants it professionally installed for any warranty claims.
So if you buy direct and have it installed you should save a bundle.

[bmwpower]

Prices here:

http://autosportsunlimited.com/trans.html

Very nice warranty:

http://autosportsunlimited.com/warranty.html

[jeff540i]

I've heard they cost around $1500-2000 but that was a couple of years ago, however the info was from a knowledgeable BMW E34 enthusiast. Call your local BMW dealer and see what it would cost from them.

Where are you located?

I'm in Pittsburgh, PA. The specific error code is #105.

Thanks for the help guys. Autosports Unlimited is probably the closest option, and seems about the best deal going for a fresh rebuild with authentic ZF parts. Looks like it'll be $2,595 + shipping and installation. Probably north of $3,500 all-in, but it beats the $4,600 I was quoted before.

[leicesterboy15]

I will have this dilemma soon. I would love to do the work myself but don't have the space or the time! If it was me I would go for the 6 speed manual conversion, probably cost about the same (it would here in the UK). Failing that I would go for a trusted second hand unit if you can't get a recon one cheaper than $4k (sounds very high to me). How about a recon on your box (new seals / oil / filters etc) and a new torque converter or is it too far gone?

[jeff540i]

I will have this dilemma soon. I would love to do the work myself but don't have the space or the time! If it was me I would go for the 6 speed manual conversion, probably cost about the same (it would here in the UK). Failing that I would go for a trusted second hand unit if you can't get a recon one cheaper than $4k (sounds very high to me). How about a recon on your box (new seals / oil / filters etc) and a new torque converter or is it too far gone?

I don't know if it's gotten to that point. The mechanic I took it to is a past president of the local BMW club and highly regarded independent mechanic. Although the quote he gave me sounds kinda high. His invoice said:

"Customer states that the "Trans Prog" warning is on mid. Necessary to read out DME, EGS, and all addressable control units. Found "Speed Monitoring" fault code #105. This indicates that there is excessive slippage in transmission. It is necessary to replace the transmission. ZF 5HP30."

I always wanted the 6spd manual, but I have no idea how to do a six speed conversion or how the cost stacks up. How do you find a shop that does one? Wouldn't it be better and more economical to just buy a 540i sport?

[Ross]

You will probably never amortize the cost of a new autobox at those prices.
A KNOWN(I know that's the tough part) used box would be my choice.
DIY is cheapest or have a shop supply the trans and labor would make them responsible for the entire job compelling them to seek a good replacement.
I still don't understand why these trannys are so friggin' expensive.

[rnrn]

but if I could do it all over again I would have paid the small difference b/n what I got and Kurt Koeller's price. He was actually instrumental in helping me diagnose the failure even though he didn't get my business. Many people swear by his trannies and work. My .02

[yaofeng]

6 speed conversion makes sense only if you can do it yourself IMO. The cost would be prohibitively high considering it is a 94. My 6 speed project lasted over a year because of my busy work schedule which also involves frequent traveling. My 95 540 I bought on Ebay for $2,750 at 144k miles. it came with a bad Nikasil. I swapped with another 63k mile Nikasil plus the 6 speed conversion. In the end the cost to me is more than $9k. My labor is of course free.

[karl1171]

Based on Yaofeng's reply I'd look for another car to use for parts, posssibly nikasil damaged, blown head gasket, accident damaged etc. No doubt these will be thin on the ground if you decide to look for one!

Depending on the condition of this you may be able to transfer good parts from your current car or the transmission from the donor car.

When all is completed you have a near complete car to either sell on to reduce your total spend, or break yourself if you have space/time (perhaps via ebay etc). This could conceivably cover the cost of the donor vehichle completely

[Tiger]

Jeff, if it was me... because I have the same car and had similar problem before... At one time, on the highway, my car stuck in 3rd gear like you... and I shifted to N and then back to D and all is well. It was fine until a couple of months later where my car wouldn't move, it was like parking brake is on. and the car can move slowly foward with harder acceleration.

I contacted Kirt and he said this is classic 5HP30 problem... the valve body needs to be rebuilt. I took it out and sent it to Kirt. He sent me a rebuilt one and I stuck it back in. Since when I took it out, it was like almost complete ATF drain... I must have collected nearly 11 quarts out of there.

I then put in Pennzoil MultiVehicle ATF... at $3 a quart. The car shifted great and grabs much more firmly... meaning the ATF was extremely dirty... It was very sedimented and blackish because it was that stupid "Lifetime" fluid.

It was about 108,000 miles when it happened to me and in 2001. Today, it is still beautiful... I don't drive much so the car still got less mileage than your car.

So if it was me, I'd stop driving the car and put in rebuilt valve body with all new ATF fluid... Pennzoil MultiVehicle ATF. There are many fluid to use Castrol European Multi Vehicle ATF, Amsoil Universal ATF, Quaker State Multi Vehicle ATF and others.

At the very least Jeff, I would drain all the fluid and refill with Pennzoil... and maybe after another 300 miles, I would do it again to flush tranny out completely. Important thing is the filter needs to be changed so you are going to have to drop the pan.

Valve body rebuild means complete selenoids change, new speed sensor, new check balls (primary culprit)... everything.

[bigtisas]

I had a trans program in my 525ia several months ago. I let the car cool down and was able to drive 100 miles home. After I arrived home, I found out the trans fluid was low, so I put in about 1.5 qtr of Dexron VI. The trans program didn't show up anymore and it's been driving fine for 2000 miles (knock wood).