The BIG ZF transmission post, all details you want RIGHT here! LONG

[Edwin NL]

Ok I have posted this on Bimmerboard also but as we are getting so many transmission questions and discussions here it was time to post.

Keep in mind this post is without any BS and all info is directly from the ZF FACTORY! and not some shop!!

(how can we get a sticky here?)
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I drove up to ZF on Thursday evening and left my car there overnight so it had time to cool down.

Here is the ZF plant in Dortmund Germany.





Before we start here some pics of a torque converter that has gone bad. (look at the inside due to low oil)







We also got a small tour:

In stock 5HP24, completely new



And some 5HP30



Old torque converters



Need a gearbox??



Car was in the same spot as I dropped her off the day before (so the gearbox is COLD!)



Now we get started



Take off the pan:



Then they took off the shifter brain: (valve body)



Brain on the cart/table:



They take it all apart?!?!?!





Look at all the junk inside the brain!



They change a lot of parts, here is the (bullet/marble) from inside that helps to drop pressure of GB when you shift. (left is my OLD one)



When they have the unit completely apart they start cleaning:







Then all parts go into a dishwasher



A new gearbox waiting to be put together



After cleaning and washing this is how it all (should) look like.







Then they start to put it all together.



They check all parts and look if it’s up to spec, if not they replace all parts.

Here you see the main pressure piston (that went in the above pic)

This is a revision on the gearbox , the job of the piston is to cut back the shock/jerk that the GB could make when put into gear. (the left is my old one)

Now I have to let the brake go or check my cluster to see if it’s in gear!



Some parts that go in: (All new)



Also new rubbers, gaskets and a new gear selector (steptronic) to make the shift smooth when your in manual. I can tell it works!

[Edwin NL]

Here the parts are in:



The new filters, rubbers and marble is in:



Assembly:









All is nicely torqued up to spec:



All done, it’s almost a shame to cover it all in oil again!





Old pan but cleaned, new gasket and magnets.
Always change magnets when you drop the pan!!



Brain back in the car



New filter



New sticker



Even ZF says this sticker is BS



Filling the GB (engine off)



Then they start the car while going through the gears they fill the GB to spec



They also did my Dif oil and checked the oil to see/smell the condition.





Filling the dif





ALL DONE! Well I thought!

Then mister Sagert takes the car for a test drive (15 miles)



After the test drive the car goes back inside, they jack it up and check for leaks and check/ retorque the bolts. ( WOW what a service!)

These guys are AWSOME they gave us coffee, drinks and some sandwiches for lunch!

Ok I know oil is less expensive in the USA but here is what I paid for this awesome service:

At the dealer here in NL the BMW LL oil is € 23 (excluding tax) per litre. (GB takes 10.5l)

For this complete service with all the parts and labour I paid € 354,00.

In my book a ABSOLUTE steal!

And now the big Q:

Did it make any difference?

HELL YEAH! OMFG, for those who have driven a E61/E60 that’s how my car shifts now.

Smooth as silk, no jerks, no noise, I have to look at the cluster to see if it’s in gear!

On the way home on the Autobahn I used the steptronic, could not feel the shifts at all!

In D doing 110 mph and using kick down also no jerk of down shifting just smooooth all the way.

Driving slowly you can not notice the shifts at all anymore I’m very happy with the result!

I would like to thank mister Sagert and his team for doing a outstanding job on my car!

ZF says to change the oil each 50k miles and fluid and filter each 100k.
Same for diff oil.
Long Life oil does not exist!!!!!!

If you have questions please ask them!!

Edwin

[2DYE4]

wow, I would love to have that done. Looks to be a bit more than I want to attempt doing a DIY. Great post!

[voodoomelon]

Wow, an absolute pleasure to read this post and oogle at the pics, great job. An that was an absolute steal!

[4liter]

Wow that is cool. Right to the ZF plant for servicing. No middle man no BS. That servicing would have been a mint to pay over here. We'd just get a rebuilt unit and pay $1.5k-$2.5k and be glad. Edwin, you made out nicely. The hat is off to you! I wish that we could get those savings too.
354 Euros = 465.7224 U.S. dollars

[Edwin NL]

I know ZF in the USA has valve body kits to do this!

[4liter]

But if we could get direct servicing like you with the sandwiches, they let you into their shop and you were able to snap off a few pics so we can see too, the world would be a better place.

[mojocoggo]

Aw man, I really wish there was somewhere in this country where one could go to get that type of service. The fact that they let you take pics shows they really have pride in their work. Most places here won't let you take pics because they do shady stuff and are violating safety regulations.

[740fizza]

Wow, really nice job Edwin. But why must you replace the magnets? In all the cars I have serviced (and seen serviced), you only need to clean them up and put them back.

[dazednkenfused]

I don't think there are any place like that in the states that service a tranny like that and if so, definitely not at that price point. I want mine done now!

[Zorack]

I say we do a road trip and head over there....Maybe we can get a group discount. Nice write up!

[Edwin NL]

Wow, really nice job Edwin. But why must you replace the magnets? In all the cars I have serviced (and seen serviced), you only need to clean them up and put them back.

The magnets loose power over time, they are $2 each for new.
I felt the strength of the old and new one and made a big difference.

[voodoomelon]

First example ever where something is cheaper over here than the States! Would almost be worth my while to drive to Germany, only 1283km!

[Zorack]

First example ever where something is cheaper over here than the States! Would almost be worth my while to drive to Germany, only 1283km!

We could take the N Atlantic goose route....Me thinks its frozen over this time of year.

[mcallister]

Where could I get that done! I bet there no shop here in the USA to do that. I guess I'll just keep the oil changed in it and let her go.

[Spitfire007]

This is a great display of quality service that, unfortunately, does not exist here in the states.
Just finding a shop that knows what they are talking about with respect to our transmissions is difficult. So, I believe that fluid should be changed, and I'm sure my valve-body redone as well (after 11 years and no fluid change), but I am NOT going to DIY this, much less a fluid change and risk messing it up.
Find me a GREAT indy in Maryland that will do a great job of this and I'll consider. Otherwise, nobody is touching it....
Sorry about my continued fear of 'crackin' the box open.

[rpape01]

Nice post. Thanks for all the pics.
The biggest part of that service is them rebuilding the brain of the transmission. Can you buy a rebuilt brain or send them yours to be rebuilt? Wonder how much that would cost??
Seems like everything else is straight forward.

[mcallister]

Nice post. Thanks for all the pics.
The biggest part of that service is them rebuilding the brain of the transmission. Can you buy a rebuilt brain or send them yours to be rebuilt? Wonder how much that would cost??
Seems like everything else is straight forward.

Edwin, that is a very good question. Would they do that, or would they just send you a new valve body? The next question would be, who in the states is actually qualified or know these transmissions like they do. Man, I would love to get this done!!

[Edwin NL]

As far as I know there are some ZF shops in the USA and I have seen Valve body kits being sold.
Not sure if you need to send out the body or that they sell the parts

[eapcpa]

Edwin NL wrote: Even ZF says this sticker is BS


I wish they would put this in writing to clear up all of the confusion. How long will it take people to realize that the purpose of "lifetime fluid" is to save BMW money under the factory service plan. They can justify not changing it and hopefully the owner will sell the car before 100k miles and buy a new one. I predict that in this current economy, cars will be kept longer and general maintenance will be neglected due to lack of funds. There will be a glut of crappy used cars of all makes on the market here in the US in a few years resulting from the lack of proper maintenance. The BMW fluid only is also a scam. Just my .02

[njdjh2o]

Thats nice, I also would pay to get that type of service, if I can find a rebuild kit, I would do it myself.

Any body know where it can be purchased.

thanks

[jmiseo2008]

Wow! Amazing!

[jiggapoo]

Are the specs (amount, how to check level) for tranny fluid change in the Bentley? Or does the manual just say that the fluid is lifetime? I'd be afraid of filling it too full. BTW, lifetime fluid from my local dealer: $23/quart. Nice.

[7series98]

Aw man, I really wish there was somewhere in this country where one could go to get that type of service. The fact that they let you take pics shows they really have pride in their work. Most places here won't let you take pics because they do shady stuff and are violating safety regulations.

yea it is sad that some places over here do shady work (like breaking other parts and telling you that you need to get this and that fixed also)

[Spitfire007]

So, does anyone have any idea of resources here in the US?
I keep looking online and I only find a place that deals with Commercial Equipment Applications.
Call one of them and they are clueless, and can't point you in any direction.