05 545i Transmission Surging Issues help!

Originally Posted by datzbmw

PLEASE GIVE ME UR OPINOIN
I have an '05 545i. I have These same issues. I have thought about replacing the mech. But don't know if it is worth it. The car has 106,000 miles and still owe about $9k on it. Apart from the mech. Issue I absolutely love the car. Would it be worth it to get the mech replaced for $4000 since out of warranty or trade the car in? Have really had only a few minor repairs on the car. I would like to keep the car as long as I could. Should I just go ahead and replace the unit? Could not doing this repair cause any future issues?
Thanx - srry so long

I have a similar question, but with less miles, and more left to pay on the loan.

I'm still under third-party warranty, but the dealer says they cannot replicate the issue.

There was talk of a class-action law suit. Can we get this going?

I just dropped my 545 at the dealer with this issue if. My question is if they say they cant find anything can I ask them to open a puma case?

I had the same issue.

My SA at one dealer told me that they would not open a PUMA case, because the Shop Foreman failed to replicate the issue. I drove with him, and showed him how the car would not switch gear properly around 40 mph, and he said it's suppose to do that. He explained a bunch of stuff that was incorrect, given the situation.

Another dealer, within the same chain, initially did not open a case, and then on another visit said they did. They said that within the PUMA case, they were sent specific software from BMW in Germany, to place on the car. Of course, that did not work, and I have not had a chance to get the car back in to them, and that was just before winter hit.

Originally Posted by aiwapro

I had the same issue.

My SA at one dealer told me that they would not open a PUMA case, because the Shop Foreman failed to replicate the issue. I drove with him, and showed him how the car would not switch gear properly around 40 mph, and he said it's suppose to do that. He explained a bunch of stuff that was incorrect, given the situation.

Another dealer, within the same chain, initially did not open a case, and then on another visit said they did. They said that within the PUMA case, they were sent specific software from BMW in Germany, to place on the car. Of course, that did not work, and I have not had a chance to get the car back in to them, and that was just before winter hit.

My SA said the same thing I am going to drive the car with the foreman and show him what I am talking about. They want me to pay for 254$ for the software I told him no. should I call BMW or wait to see what they say. I only have 30 days left on my cpo warranty.

Originally Posted by aiwapro

I have a similar question, but with less miles, and more left to pay on the loan.

I'm still under third-party warranty, but the dealer says they cannot replicate the issue.

There was talk of a class-action law suit. Can we get this going?

I am down with the class-action law suit.

Update i just came back from the dealership and showed them what I was taking about. The can will not do a slam but it did have a hicpup coming to a stop and taking off. The SA said I dont think any of this will be covered I am pissed but still waiting for the SA to get back to me. I am getting very aggrevated what should I do at this point?

So here is the update just got back form the dealer and they updated the softwar on my tranny . When i asked him what is the new version he gave me this number is this right.e060-11-03-501.

Originally Posted by bryant

Tommy, yes they are. The mech unit has yet to come in, so it's still been waiting at the shop. Apparently it had to be programmed first and that contributed to the delay. I'll give you a report once I get the car back. Feeling a little anxiety.

Who sent it for programming and where? Mechanic sent to the dealer?

I am having a different problem. My transmission does not always respond when manually shifting. I attempt to downshift, sometime it responds correctly, some times it does not respond at all and other times it may upshift. Anyone else sen this? I have also seen it downshift all the way to 1 (by itself) when stopping.

Originally Posted by bryant

Thanks for your confirmations. After driving a couple hundred miles now, I continue to be pleased. Not only is the problem fixed, I can really tell the car is more responsive. I wonder if it has to do with the programming on the new unit versus the programming on my old unit or perhaps that the new unit is well, new, lol. I recall when I first got my 545, that I told the dealership that it felt it was too "jolty" when I accelerated from 0. They changed the programming and fixed that, but I always thought I was robbed of a little power. After the install of the new unit, that power feels like it has returned. Keep in mind this is all theory. The main thing is is that those annoying hiccups are gone.

Do you have a copy of your invoice. I want to show this to my dealer. I am here now, for probably the 4th time, and they said the issue is normal.

It seems clear here that dealers know full well the issue and are simply attempting to run out the clock. I was very lucky and had a complete tranny failure before CPO expired but before that they were pissing me off pretty good and had done a $800 bushing change they damn well knew would not fix the issue.

They would have been better served to change their fluid change interval to every 30k and run out the clock and mileage that way.

Note: My k does mean kilometers.

I agree. However, I have a 3rd party warranty, and they still will not move forward.

My beloved 05 545 has been at the dealer since the last week of June. While driving aggressively one day it made a big slip going from 4th to 5th and the trans malfunction warning came up on idrive. Took it in (one year power train warranty came with the car) and they said the tranny needed replaced. As it is not CPO they put a used tranny in, picked up the car and anytime it is in 5th gear it would surge and if you drove it hard the idrive warning would come up. Took it back and the dealer opened a puma case with BMW and were given "special" permission to completely erase and reflash the mechatronics unit. Picked the car up and it was worse than ever... Hard shifts, surging in 5th, and idrive warning if driven hard. Took it back and they said the tranny was bad and needed to be replaced. Replaced with yet another used tranny, did the whole magic reflash thing again and called my wife this morning to come get it and that it was fixed. She picked it up and immediately noticed that it still surges, she went back and took their tech for a ride and he felt the surge as well so they put us back in a loaner. They called her this afternoon and claimed that they called a "specialist" in Michigan who says surging is completely normal and told her to come get the car. She argued that the 3 different loaners we had didn't surge, her X5 does not surge, nor have the last 3 BMWs we've owned. They again said it's normal and to take the car. I have the service history of the car and the original owner complained about the transmission while it was under factory warranty but nothing was done about it. Is there anything at all I can do? I've requested that someone from BMW corporate contact me (part of the dealer survey) but not sure if that will go anywhere or not. This thread was mostly to rant but if anyone has any decent advice or experience I would appreciate hearing it. Thanks.....

I got the run around for a while with BMW under a cpo warranty for this issue and they finally replaced the mechatronics value assembly and that completely resolved it. Previous fixes they tried were servicing the tranny and updating software. Good luck, you need to demand mechatronics replacement.

Originally Posted by Locomotivebart

I have the service history of the car and the original owner complained about the transmission while it was under factory warranty but nothing was done about it. Is there anything at all I can do? I've requested that someone from BMW corporate contact me (part of the dealer survey) but not sure if that will go anywhere or not. This thread was mostly to rant but if anyone has any decent advice or experience I would appreciate hearing it. Thanks.....

I don't see any other way as to sue them - I have pretty appalling experience with BMW service under CPO myself. If you can show that other cars don't have these issues and provide a couple of supporting reports from indys - any court in sane mind should give you a win - BMW essentially denies warranty repairs while under warranty contract.

BMW USA not going to help - waste of time.
I had a great experience with Audi Germany when complaining on a leaking turbo engine - unlike BMW, Audi really stands behind their products.

Where was the Specialist that came from Michigan, from? I america in michigan, and am having trouble getting this properly diagnosed as well. They just ignore the obvious, and do everything that is not the solution. How can we all be wrong. I have even provided invoices from dealers who have correctly diagnosed and successfully repaired the problem by replacing the Mechatronics, and yet my local dealer ignores it.

I am seriously considering switching brands. I thought Porsche, but don't care for their interiors. Perhaps Audi is an option, given the customer satisfaction stated from the previous poster.

Originally Posted by aiwapro

Where was the Specialist that came from Michigan, from? I america in michigan, and am having trouble getting this properly diagnosed as well. They just ignore the obvious, and do everything that is not the solution. How can we all be wrong. I have even provided invoices from dealers who have correctly diagnosed and successfully repaired the problem by replacing the Mechatronics, and yet my local dealer ignores it.

I am seriously considering switching brands. I thought Porsche, but don't care for their interiors. Perhaps Audi is an option, given the customer satisfaction stated from the previous poster.

All they told me was that a specialist from BMW came from Michigan, drove the car, and said it was perfectly normal. Right after that we filed a complaint with bmwna as we had the car an hour before having to take it back.

I have filed a complaint as well. They didn't do anything, but just said the complaint would go on record for the dealership. I don't care about that. I just want the car fixed. Ahh. I don't know what to do. I don't want the car anymore. The shifting is just completely unpredictable.

Dealer called this morning to inform us that they are putting a NEW transmission and mechatronics in my car. I guess patience pays.

There is a valve body repair kit available. It can be completed without dropping the transmission. Two hours labor. My 545i does the same thing between 35 & 40 mph. I'm going to have my fixed with the kit.

Originally Posted by Cuddy

There is a valve body repair kit available. It can be completed without dropping the transmission. Two hours labor. My 545i does the same thing between 35 & 40 mph. I'm going to have my fixed with the kit.

Any more info? If this is true, it could probably help quite a few people out.

Hi Roger,
My name is Anthony we have emailed each other regarding flat paddles on my 645ci. I have was considering the paddles with the leather inserts...
I'm glad to find you here because you will understand why it takes me time to decide to go for the change of steering wheel... Reason being I have issues with my tranny. And if I need to change the mechatronics I might as well change the car and go for a 650 with the SMG gear box with the paddles...
Really hoping to find other possible source to my problem.
Regards

New to the forum. I have also having the surging issue in 5th gear only between 35-40 and part throttle in my 04 530i auto. Very annoying, but has anyone had a real transmission failure? Or is it more of an annoyance? Don't have a warranty and just wondering if this problem will develop into something more if not addressed. I Just noticed this problem last week and was about to trade it in on a M3 but i would prefer to hold out a while if issue is not that urgent! Any responses would be appreciated. Thanks.

I just bought a 2006 525i. Does anyone know of a good extended warranty that I could purchase?

I decided to write ZF and see if they could offer any suggestions. I thought they offered a candid response which is appreciated.

My message to ZF:

I am hoping you might be able to offer a suggestion. I have a BMW 545i with the GA6HP26Z transmission. As of late it has what many others have accurately described as a 'hiccup' when at low RPMS 1200-1500 at 30 and 40 mph. It is as if the transmission cannot make up its mind if it wants to downshift or stay put causing slight but noticeable hesitations. I took my vehicle to the BMW dealer and they noticed the mechatronics sleeve is leaking slightly but could not identify if that is the problem. I've done a fair amount of research and many have started with the sleeve replacement but have not had any resolution. It is a hefty repair so I do not care to just spend $1,000 to 'maybe' fix the transmission problem. I spoke with BMW of North America to see if they have compiled which seem to be plentiful complaints regarding this problem to come up with a sure-fix resolution, but they have nothing. Do you have any recommendations? The biggest frustration is having several dealerships apparently not collaborating and throwing different possible solutions, only to cost a bunch of money and leave the problem unresolved.

ZF response:

Thank you for contacting the ZF Automotive technology Group North America. The situation you describe is rarely if ever fixed by replacing the mechatronic electrical sleeve. The sleeve is the source of the leak but low oil or damage due to low oil is the cause. Unfortunately replacing the sleeve will not fix the internal damage. You have followed the correct path by having your local dealer inspect the vehicle, I'm sure they checked for software updates and presented these to you if available. Normal internal wear along with driving style and fluid aging may cause these problems. I agree the cost to replace the sleeve and obtain a possible fix is obsessive. The ZF transmission like most others on the road today are developed to compensate for normal wear through adaptive programming. This is done to maintain shift quality as well as fuel efficiency and emissions. The adaptive programming will compensate for internal wear recalculating clutch apply and release pressures. I can not recommend a specific part to change that will fix this complaint, rather I recommend having a local service center replace the transmission fluid and filter and while the pan is down service the sleeve as it is an easy repair. It is critical that only BMW 6HP transmission fluid is used with the 6HP transmission. Other fluids have not been test and may worsen the condition or cause failure. After the fluid has been changed the adaptive's need to be reset. There are two ways to achieve this, your local dealer or possibly a qualified other local service center can clear them. After the adaptions have been cleared it is necessary to perform an adaption drive and provide the needed speed, throttle and acceleration/deceleration to force the adaption's to take place. Normal driving will allow new adaptions but often requires 500 miles or more for all the correct criteria to be met before the adaptions are allowed. The adaption drive is as follows:



Vehicle at operating temperature

Step 1

From standstill execrate with very light throttle to 4th gear.

With slightly higher throttle accelerate to 6th gear.

Allow the vehicle to coast to approximately 25mph then slow to a standstill with light brake.

With brakes applied and at standstill allow to wait 10 seconds.

Repeat procedure ten times.



Step 2

Accelerate to approximately 45 mph and use Steptronic to select 5th gear.

With light throttle 60 mph then coast to approximately 40mph without using the brakes.

Repeat four times.

Accelerate to 65 mph and use the Steptronic to select 6th gear.

Allow to coast to approximately 50 mph with out brakes.

Repeat four times.

Use Steptronic to select 4th gear and repeat Step 2 from the beginning.



Step 3

With vehicle at standstill shift from M neutral to drive, wait five seconds then shift back to neutral again.

With vehicle at standstill shift from M neutral to reverse, wait five seconds then back to neutral again.

Repeat four times.



This procedure will force the adaptions and noticeable improvement should be felt.

Please be very carful and only perform this in an open area away from traffic. If the problem returns there is potential for internal damage or wear and transmission replacement or rebuild may be required. There is not an easy fix for this, due to the complexity of the vehicle and its operating systems labor and some material costs will be incurred to diagnose the problem.