E53 D-sport 3004 Auto Box swap out

[X5-D-Sport]

I need to change the auto box in my 2004 D-Sport when the sun shines again...

Question:
Will a replacement box need to be mapped to the vehicle, or can I just get another+ torque converter & do it myself one weekend.

Doing the job isn't an issue, but I don't have the mapping/configuring equipment.

Happy Easter to all.

[X5Sport]

No coding to the vehicle, but the box will need to be from an E53 like yours in order that the Mechatronics Module has the right ‘program’.  If using your current MM then no issue - it’s the bottom module under the box itself.

If you are doing it all yourself, then no problem as you are reusing the same main box.

Are you going to replace brake/clutch band materials too?  When mine was done the repairer uses a ZF ‘major overhaul kit’ so I assume it’s an off the shelf product.

The MM should be fine as they very rarely fail - but are (or were) £3k from ZF on their own 

Mine was reprogrammed by the local Bosch Autocentre.  I’m not certain there was anything wrong with the original one but the warranty company was paying so......

[X5-D-Sport]

In Birmingham there are a few Indy's who specialize in X5 Gearbox refurb replacements & give 6 months unlimited mileage on them.... may be easier to let them do the job & get it right.

[henrym3]

I thought you were just on about buying another known working box plus TC and doing a straight swap over. What's wrong with your present box.

[X5-D-Sport]

Hi Henry,
the present GearBox has done 187k miles & I believe is the original unit.
It works fine - most of the time, but when cold, I have to either pull away in 2nd in manual mode, or be VERY gently, as she will change up from 1st to 2nd with the most amazing BANG, as if no clutch function.

I understand the issue is caused by the little pistons in the mechatronic unit that have rubber tips on the ends, the rubber tips have hardened & flattened, thus not absorbing the gear change & allowing the clutches to play their part.

I have got used to getting her to change up without this massive bang that is felt thru the whole vehicle, but there is no way I can let any one else drive it without smashing the gear-box to pieces in one go.

It's been like it for 2 years now & I decided to get it fixed.

When the weather temperature is above 10'C, there is no problem, but temps like now is the issue.

I have done the gearbox oil & filter tray change at great expense, but it made no difference at all.

I chased up a cost of repairing/refurbing the Mechatronic module chunk, but that came to approx £700 on it's own, & I can buy a used box & torque converter with just 80k on it from about £700 or £1200 for a recon swap out.

Hence, finding a few auto-box dedicated Indy's who specialize in this work, & do a 24hr turnaround with a box & torque converter to hand.

[henrym3]

It's still quite a hard decision to make, potentially the £700 box could have another 100k on it and if it done that it would be £700 well spent.  The refurb at £1200 is potentially like new, depends what they mean by refurb, if it's oil and filter then that's not much of a refurb. It would I'm sure from your point of view be interesting (if you get your old box back) to pull it to pieces and see if you could see what the problem was.

[X5Sport]

Always worth asking what a ‘refurb’ does actually involve.

Taking the 18 hours of labour off mine when it was done then it probably equates to around £1,500.

In my case they fitted a ZF major overhaul kit, new oil pump, new filter, gaskets, new (not remanufactured) torque converter and fluids, plus a 12-month warranty with a service after 1,000 miles.

[fenj66]

[quote="X5-D-Sport Salisbury"]
Hi Henry,
the present GearBox has done 187k miles & I believe is the original unit.
It works fine - most of the time, but when cold, I have to either pull away in 2nd in manual mode, or be VERY gently, as she will change up from 1st to 2nd with the most amazing BANG, as if no clutch function.

I understand the issue is caused by the little pistons in the mechatronic unit that have rubber tips on the ends, the rubber tips have hardened & flattened, thus not absorbing the gear change & allowing the clutches to play their part.

I have got used to getting her to change up without this massive bang that is felt thru the whole vehicle, but there is no way I can let any one else drive it without smashing the gear-box to pieces in one go.

It's been like it for 2 years now & I decided to get it fixed.

When the weather temperature is above 10'C, there is no problem, but temps like now is the issue.

I have done the gearbox oil & filter tray change at great expense, but it made no difference at all.

I chased up a cost of repairing/refurbing the Mechatronic module chunk, but that came to approx £700 on it's own, & I can buy a used box & torque converter with just 80k on it from about £700 or £1200 for a recon swap out.

Hence, finding a few auto-box dedicated Indy's who specialize in this work, & do a 24hr turnaround with a box & torque converter to hand.
[/quote]


mine did that also, only started after changing the gearbox oil.  >:( >:(
you kind of got used to it and could anticipate the bang and let off the throttle for a second and it would change up smoothly. was always ok after driving a mile or so and warmed up.
that was the main reason i let the car go cheaply.
i often wonder where she ended up!  ::)