ZF 5HP19 Facts, Document, troubleshooting

ZF authorized service locations

Originally Posted by doru

ZF authorized service locations

Interesting, not too many auto only or www.dosebmw.com, maybe being a ZF "SP" is not the same thing...

Great thread! I did a pan drop with a filter change at 85,000. At 95,000 no problems. Used Valveoline MaxLife fluid.

Originally Posted by shenecke

Great thread! I did a pan drop with a filter change at 85,000. At 95,000 no problems. Used Valveoline MaxLife fluid.

I'm about to do a Valvoline MaxLife Dex/Merc ATF 12qt flush this weekend... the one ZF guy I spoke with that seemed to know his stuff said ESSO / LifeTime or Valvoline and he has done hundreds of our ZF tranny's. I'm told the MaxLife adds friction components for older 75,000+ transmissions as well as seal softeners, seems like some of the "better" ATF's (which likely are actually purer products) like RedLine, Royal Purple might be too slippery leading to issues that have been well discussed. I'll post my results in hopes it helps others getting ready to jump off the cliff! Going to go either Royal Purple or RedLine in Engine and Rear Differential at the same time.

Hi, my torque converter was changed 8 days ago i have have the same trouble, but my transmission light go on only when i run in 45-55mph (lower speed), when im on the highway 60-80mph (high speed) my transmission light never come on, since this time a have a lot of opinion, some people told me that is the sensor of the pump in the tranny or the valve body, other people told me for the mass air flow or a intake leak can cause a tc slip all people are bmw technician.....now i will wait because i dont want to lose more money. Sorry my english is not very good.

Originally Posted by sebasl78

Hi, my torque converter was changed 8 days ago i have have the same trouble, but my transmission light go on only when i run in 45-55mph (lower speed), when im on the highway 60-80mph (high speed) my transmission light never come on, since this time a have a lot of opinion, some people told me that is the sensor of the pump in the tranny or the valve body, other people told me for the mass air flow or a intake leak can cause a tc slip all people are bmw technician.....now i will wait because i dont want to lose more money. Sorry my english is not very good.

That stinks. My fear exactly. Change the TC and code 48 still occurs. Now that u mention it my SES only pops on when I'm below 55, never on highway. In fact often it is from 2nd to 3rd either an upshift or downshift. Can u detail the MAF issue the BMW tech saw that resulted in a code 48. That is new to me. What ATF did u use after the TC replacement?

I just spoke with a transmission technician specialized in ZF tranny and he are sure that is the valve body, i will change this parts next week, for the MAF if the sensor have trouble or if you disconnect this sensor the tranny light will come in the dash. But my transmission run and shift very well. For the slip problem all technician told me that is a pressure problem for the torque slippage, and only changing the torque will not correct the trouble.

Originally Posted by sebasl78

I just spoke with a transmission technician specialized in ZF tranny and he are sure that is the valve body, i will change this parts next week, for the MAF if the sensor have trouble or if you disconnect this sensor the tranny light will come in the dash. But my transmission run and shift very well. For the slip problem all technician told me that is a pressure problem for the torque slippage, and only changing the torque will not correct the trouble.

Is your transmission kicking out CODE 48 even after changing the TC? Did you get the old TC back so you can see if the seal is torn like in the TSB image. Seems like some guess work if you are now changing the valve body too... keep us posted, this hits close to home on my issue.

yes i have my TC but the seal are in good condition...i found this information on the net and its for this reason that the technician change the torque:

CAUSE
Possible cause: deterioration of the torque converter turbine shaft seal

PROCEDURE

Remove the torque converter. For the removal procedure, refer to Repair Manual RA24 40 002.


2. Drain the fluid out of the torque converter, and carefully inspect the turbine shaft seal (1) INSIDE THE BOTTOM OF THE TORQUE CONVERTER for signs of damage (cracks, splits, etc.).Helpful Hints:
3. Use a small flashlight to illuminate inside the bottom of the torque converter to examine the turbine shaft seal. The turbine seal is brownish orange in color and measures approximately 1" in diameter.
If evidence of seal deterioration is found, replace the torque converter.

But the technician say that the seal can have small deterioration but this case dont change any problem.

And before we change the TC i do a oil flush with the filter and i refill with the esso 22$ each but my friend have a part store and i paid only 16$ each but not change the situation.

Originally Posted by sebasl78

And before we change the TC i do a oil flush with the filter and i refill with the esso 22$ each but my friend have a part store and i paid only 16$ each but not change the situation.

That really is too bad... you are doing everything I'm about to do. I would be bummed out if I did an ESSO flush / filter / TC and still HAD the damn Code 48! I'm doing a $4 Valvoline MaxLife flush / filter then electrical tape over the SES light!

How many miles on your car? Did you ever go into TRANS SAFE MODE? My car did when the alternator died, so I'm wondering if the engaged solenoid got damaged when the car "thunked" into TRANS SAFE MODE...

No its the first time, my car have 95000 milles if you have this trouble since your alternator trouble, maybe if its the TCC solenoid the trouble would be permanent and not intermitent, you can go to a shop only to check the solenoid, but if you have an aftermarket alternator i found this information:

PROCEDURE
1. NEW Inspect vehicle for presence of various, non-approved aftermarket electrical equipment. If such an equipment is installed, contact a customer and with his/her permission disconnect it (remove it) from the vehicle.

2. NEW In case a customer does not wish to remove aftermarket equipment which may be causing an electromagnetic interference, provide him/her with an option of installing a special EGS control module (step 5 of this procedure). This repair and diagnostic time would NOT be covered by BMW warranties (customer pays for parts and labor).

3. In case aftermarket equipment is not found, then inspect connections and repair if needed at:

- Battery terminals,
- Battery ground connection,
- Ground/B+ splices/connection in engine and body harness,
- Ground connection at the ignition secondary windings, etc.


My friend got the same trouble last year but it was only a low oil level.....

Originally Posted by sebasl78

No its the first time, my car have 95000 milles if you have this trouble since your alternator trouble, maybe if its the TCC solenoid the trouble would be permanent and not intermitent, you can go to a shop only to check the solenoid, but if you have an aftermarket alternator i found this information:

PROCEDURE
1. NEW Inspect vehicle for presence of various, non-approved aftermarket electrical equipment. If such an equipment is installed, contact a customer and with his/her permission disconnect it (remove it) from the vehicle.

2. NEW In case a customer does not wish to remove aftermarket equipment which may be causing an electromagnetic interference, provide him/her with an option of installing a special EGS control module (step 5 of this procedure). This repair and diagnostic time would NOT be covered by BMW warranties (customer pays for parts and labor).

3. In case aftermarket equipment is not found, then inspect connections and repair if needed at:

- Battery terminals,
- Battery ground connection,
- Ground/B+ splices/connection in engine and body harness,
- Ground connection at the ignition secondary windings, etc.


My friend got the same trouble last year but it was only a low oil level.....

I have a completely stock electrical system but my battery "viewport" shows black which means not fully charged vs. green (fully charged). I'm considering pulling the battery, doing a battery "condition" which is on my smart charger to see if I can restore it to green... I would hate to drop the transmission and end up chasing demons like you are now with the valve body.

I'm starting with:

1. a Valvoline MaxLife trans flush / pan drop / filter
2. condition the battery to get back to green
3. black electrical tape over the SES light : ) drive 'er like I stole it!

I just posted my experience repairing the P0741 torque converter code at http://www.bimmerfest.com/forums/sho...=1#post5288886.

FYI, if you get the SES light on due to this code, you might be able to temporarily get rid of it enough to pass the emission test, by resetting all OBD codes and then running through the drive cycle to reset the Readiness Monitors just before you go for your test; but the only permanent solution is to replace the Torque Converter. The fault code starts as a "pending code" in the computer (doesn't light SES light) until converter lock failures exceed some fault count; then the code becomes a hard code and lights the SES light.

Confusingly, the Bentleys seem to refer to different numbers than ZF 5HP19. For example, my 525i 2002 is listed as having a A5S 325Z automatic transmission; but, I'm told elsewhere this is the same as the ZF 5HP19.

Can someone say, for sure, which OTHER designations in the Bentleys also refer to the ZF 5HP19 automatic transmission (see chart below).

Also, from this thread, a short summary of the fluids to use are in this glovebox printout.

- Automatic transmission (green sticker): BMW PN: 83.22.0.024.359 or Texaco ETL 8072B or Shell LA2634 (this is extremely confusing, not only because these are cryptic "types" but also because the Bentleys list different fluids and volumes on page 020-10, 240-6, & 240-8). [Volume w/o torque converter/with torque converter total: Type 525i A5S 25Z 6.5/9.4 qts, Type 530i A5S 25Z 6.4/9.3 qts, Type A5S 310Z=3.5/8.2 qts, Type A5S 360R & A5S 390R=4.2/9.5 qts, Type A5S 440Z=4.2/10.2 qts, , A4S 310R 3.5/8.3 qts, Type A5S 560Z 5.8/13.8 qts]. Replacement Interval: Lifetime oil (Bentley 240-6); but the user-recommended replacement interval for the fluid and filter is roughly 5 years or about 60K miles. Apparently Pentosin is the OEM oil but FEBI also works (ATF Auto Transmission Fluid equivalent to ESSO LT 71141). Note: Mixing ATF types will cause transmission failure (Bentley 240-6). My 2002 525i with the ZF 5HP19 (aka A5S 325Z) transmission (6.2 liters/8.9 liters or 6.6 quarts/9.4 quarts) has this green sticker.

BMW transmission fluid chart. See attachment. Has the details Bluebee is looking for.

Same as above, but more complete, with torque specs, temp specs etc (Bentley publishers)

Originally Posted by gtxragtop

Has the details Bluebee is looking for.

Thanks.

Here's a summary based on that automatic-transmission PDF & the Bentley charts below.

E39 Manual transmissions:
BMW 525i 2001-2002 M52TU, M54: Getrag S5D 250G, 1.2 quarts (1.1 liters)
BMW 540i 1997-2002 M62: ZF S6S 420G, 2.0 quarts (1.9 liters)
BMW 528i 1997-2002 M52: ZF S5D 320Z, 1.4 quarts (1.3 liters)
BMW 530i 2001-2002 M54: ZF S5D 320Z, 1.4 quarts (1.3 liters)

E39 Automatic transmissions:
GM THM-R1 (A4S 270R), 9.3 quarts/8.2 quarts (8.8 liters/7.8 liters)
BMW 528i to 9/1999 M52: GM THM-R1 (A4S 310R), 9.3 quarts/8.2 quarts (8.8 liters/7.8 liters)
BMW 528i after 8/1999: GM 5L40-E/GM5 (A5S 360R), 9.5 quarts/8.5 quarts (9.0 liters/8.0 liters)
BMW 525i to 3/2001 M54: GM 5L40-E/GM5 (A5S 390R), 9.5 quarts/8.5 quarts (9.0 liters/8.0 liters)
BMW X5 GM 5L40-E/GM5 (A5S 390R), 10.1 quarts/9.1 quarts (9.6 liters/8.6 liters)
BMW 530i to 3/2001 M54: GM 5L40-E/GM5 (A5S 390R), ? quarts/? quarts (? liters/?liters)
ZF 4HP22, 7.9 quarts/3.2 quarts (7.5 liters/3.0 liters)
ZF 4HP24, 8.6 quarts/3.3 quarts (8.1 liters/3.1 liters)
ZF 5HP18 (A5S 310Z), 8.2 quarts/3.4 quarts (7.8 liters/3.2 liters)
BMW 525i from 3/2001 (2.5L M54): ZF 5HP19 (A5S 325Z), 9.4 quarts/6.6 quarts (8.9 liters/6.2 liters)
BMW 530i from 3/2001 (3.0L M54): ZF 5HP19 (A5S 325Z), 9.2 quarts/6.5 quarts (8.7 liters/6.1 liters)
ZF 5HP24 (A5S 440Z) for 4.4 L, 9.5 quarts/5.7 quarts (9.0 liters/5.35 liters)
BMW 540i from 1/1997 M62 TU: ZF 5HP24 (A5S 440Z) for 4.6 L, 10.5 quarts/5.7 quarts (9.9 liters/5.35 liters)
BMW 540i to 1/1997 M62: ZF 5HP30 (A5S 560Z) 13.8 quarts/5.8 quarts (13.1 liters/5.5 liters)

QUESTION:
What is the purpose/reason for the two different designations of the automatic transmissions (e.g., ZF 5HP19 vs A5S 325Z)?

Note: Of interest is that you have to call BMW if you replace a transmission (what would you do with the code they provide you anyway?); and that the GM transmissions have a vastly smaller difference with and without the torque converter versus the ZF transmissions.

Originally Posted by doru

Same as above, but more complete

One by one, I'm cross referencing this information into the transmission fluids thread. Notice the Bentleys use a different identification system which isn't unique to the transmission! For example, the A5S 325Z, confusingly, has TWO different sets of fluid volumes!)

Originally Posted by bluebee

Notice the Bentleys use a different identification system which isn't unique to the transmission! For example, the A5S 325Z, confusingly, has TWO different sets of fluid volumes!)

There are 2 different M54 engines. One has a 2500 cc displacement, the other one has 3000 cc. So the difference is probably due to a slightly bigger tranny radiator. Not sure, because I did not check, but I believe that's where that difference goes. Not in the tranny itself.

Originally Posted by doru

So the difference is probably due to a slightly bigger tranny radiator.

That's a very good guess ... at least it makes sense out of the data (how can a ZF 5HP19 take different fluid volumes otherwise)... Thanks.

At least now, finally, we have really known volumes, by transmission & by car.

Since the E39 transmission fluids thread was only 'by transmission', I'll have to add the 'by car' part also.

BTW, WHY do they use these differing designations anyway? (ZF 5HP19 in the TIS versus A5S 325Z in the Bentleys)?

Originally Posted by bluebee

That's a very good guess ... at least it makes sense out of the data (how can a ZF 5HP19 take different fluid volumes otherwise)... Thanks.

At least now, finally, we have really known volumes, by transmission & by car.

Since the E39 transmission fluids thread was only 'by transmission', I'll have to add the 'by car' part also.

BTW, WHY do they use these differing designations anyway? (ZF 5HP19 in the TIS versus A5S 325Z in the Bentleys)?

Call the dealer and ask.
Also, it doesn't really matter what the written capacity is IMO.
Just keep track of the amount that came out, and refill accordingly.
Besides, when refilling, you fill until it over-flows.
Similar to replacing the differential fluid and the manual transmission fluid.

Originally Posted by bluebee

That's a very good guess ... at least it makes sense out of the data (how can a ZF 5HP19 take different fluid volumes otherwise)... Thanks.

At least now, finally, we have really known volumes, by transmission & by car.

Since the E39 transmission fluids thread was only 'by transmission', I'll have to add the 'by car' part also.

BTW, WHY do they use these differing designations anyway? (ZF 5HP19 in the TIS versus A5S 325Z in the Bentleys)?

2003
530 cooler 17221740798 $338.52
525 cooler 17221740798 $338.52

Nope, same part number.... Keep fishing

530 Torque converter U61 24407519535
525 Torque converter C51 24407509115

530 transmission EH A5S 325Z - TU 24001423933
525 transmission EH A5S 325Z - TT 24001423931

Since the capacity is off by .2/.1 with or without the torque converter means that there are different transmission versions backed up by the part numbers.

so my TC is out and im gonna get my valve body recalibrated here http://www.517trans.com/ my contact works with alot of B5S4 guys with tip... im getting my TC repaired and beefed up. looking at all the reviewsfor 517trans and sam im gonna say they are good in my books... we shall see how their work is post repairs....

thanks for the links its helping alot

Originally Posted by gtxragtop

Since the capacity is off by .2/.1 with or without the torque converter means that there are different transmission versions backed up by the part numbers.

Wow. Good research! It seems, based on what you found out, that the PART NUMBERS are different (hence the volumes are slightly different) but all other transmission-identification numbers (ZF 5HP19 or A5S 325Z) are the same. Verrry confusing. Do we know WHY they use different numbers for what appears to be the same transmission otherwise? (e.g., ZF 5HP19 or A5S 325Z are the same, yet even that isn't enough information to distinguish them ... you have to get the BMW part number for your particular vehicle).