After some great help from CTSC, I finally figured the solenoid 4E87 is outside the trans above the top of the gear shift. In order to get to it, you have pull out the following in sequence.
1. Hazard switch
2. Panel holding the air vents
3. Front panel containing the controls to AC etc
4. Lower panel where your NAV DVD section.
5. The centre knob
6. Menu switch
7. Gear shift knob + cover + drive panel (which indicate which gear you are in)
8. The complete mid section panel.
9. Cigarette lighter holder
And now finally if you see right above the gear shift, you will see a cable going into the gear shift. That little connector wire is going into the solenoid 4E87 (picture attached). Now back to my problem. During cold start I get a warning for this solenoid not being functional and then it disappears after few minutes. I have checked the solenoid is fine to its resistance of 19-21 Ohms, and the connecting cable has the right voltage during the day time, but strangely at cold start, the cable does not have any voltage at all for few minutes thus causing that fault message.
Does anyone has any idea why the cable will not have voltage for first few minutes? Anyone good with BMW WDS and know where the current in this cable is coming from that I can diagnose further?
If you hadn't tested the voltage on the solenoid I would have suggested you check to see if a soft drink had been spilled into the console and the solenoid was sticking.
I assume you checked the connector and pins to make sure they were making a positive contact and didn't need to be cleaned.
The fact that you begin to receive this signal after a few minutes of warm up leads me to believe that the generation of the signal has to do with heat and expansion at an electrical connection or solenoid.
The voltage is received from the TCM or Transmission Control Module, which in turn receives the signal from magnetic valve solenoids in the mechatronics unit of the transmission. There is also interaction from the ECM.
Failure of the solenoid, TCM or any electrical connections in between can interrupt the signal.
The attached PDF is for the same transmission, but specific to a 2002 745i. It explains the operation of the MV or magnetic valve solenoids and which one controls the transmission lock solenoid.
As you dig deeper into the TCM you should be able to isolate which pins bring the signal from the transmission for the transmission lock. If the TCM is getting the signal then it is the wiring between the TCM and console or the TCM itself.
I will keep my fingers crossed for you that the problem is outside the transmission. Pulling out the mechatronics unit is not for the faint of heart and pretty high on the DIY scale of difficulty.
In the PDF the writer's problem was the solenoid was stuck in the locked position, preventing the transmission from being taken out of park. Your problem is after you put it back into park the solenoid is not returning to the locked position, thus when you start the car the next time the ECM and TCM module system checks on start up sense the solenoid out of position and you throw a fault.
Thanks for the PDF, if I look at the diagram at the bottom, it indicates 4E87 is connected directly to Ignition Switch Interlock. So how do I test that part?
The normal sequence, as I understand it is this:
Car is in park and engine is off. There is no voltage to solenoid and it is in the extended locked position.
Engine is turned on and brake pedal is depressed. Voltage is then sent to locking solenoid which is energized and retracts the locking pin to allow gear shift lever to be moved.
When gear shift lever is returned to park (engine running) the voltage to the solenoid is interrupted and the solenoid spring returns it to the locked position and gear shift lever is locked again until brake pedal is again depressed.
Sequence of your car:
Apparently when you return the gear shift to park the solenoid is not releasing and returning to the lock position. Even after you turn the engine off, and the voltage should have been released the solenoid is still not returning to the lock position.
When you start the car the computer runs through a series of checks to see what micro switches are opened and closed and what modules successfully run their start up check lists. The physical position of the locking pin on the gear shift lever is signaling the ECM that it is not in its proper position, which generate the warning that the gear shift lever can be moved without depressing the brake.
You need to answer "Why isn't the solenoid returning to the lock position?"
I can think of only two possibilities:
1. The voltage is not being removed for some reason. I believe you could test this. Put the gear shift lever in park and turn off the car. Remove the negative battery cable which should remove all power from the car and discontinue any voltage that might still be applied to the solenoid. Reconnect the battery cable and start the car. If you don't get the warning then you have interrupted the voltage that continues to be applied to the solenoid and need to trouble shoot from there.
2. The solenoid is physically being prevented from returning to the lock position after the voltage is removed. I believe this is your problem. Is the spring broken? Is the solenoid locking pin not lining up with the locking hole? Is the solenoid sticky from a spilled drink? You might try to wiggle the gear shift lever once you return it to park to see if a misaligned pin "finds" the hole.
CTSC gave you the resistance of the solenoid. Did they give you the activation voltage that is sent to the solenoid? If you know this you can pull off the connector you circled in your picture and apply that voltage at will to the solenoid and see if it pulls out of the locked position and retracts when the voltage is removed.
After you run the check for the first possibility I think you will move to the second possibility and will probably need to dig deeper into the gear shift assembly to see the solenoid work and see why it is not physically releasing to the locked position.
Thank you BimmerFan32 for such a descriptive suggestion, but I am confused why does this warning only comes in the cold start in the morning? Everything functions fine i.e. "Solenoid returns to the lock position" during the entire day time, but just not on the cold start. CTSC guys did not give me the solenoid but I know when everything is working there is a voltage of 12.something without break press and 0.01/2 with break being pressed. Is there any other diagnosis I do further?
Upon further investigation I have discovered that there are two locking systems on the gear shift lever for 2004-2007 E60s, and the solenoid operated lock is only operational when the engine is running.
The first is a cable linking the ignition lock to the gear shift lever. The key can only be removed when the gear shift lever is in park. Moving the gear shift lever to park also operates a cable connected to the mechatronics transmission to lock the transmission output shaft. Conversely, the gear shift lever can only be moved out of park if the key is inserted and turned to a least the first position.
A second locking system is employed when the car is started and the shift lever is in the P or N position. The transmission control module sends a voltage to the locking solenoid to move it to a locked position. When the brake is depressed the voltage returns to zero and the pin retracts.
Either the mechatronics unit is not sending the signal or the TCM is not forwarding the voltage.
If you don't see the voltage to the solenoid on cold start up, but do see it after having driven the car, turned it off and restart it then I would guess it is the solenoid in the mechatronics unit that sends the signal to the TCM to send voltage to the gear shift lever solenoid. The mechatronics solenoid may not be operating unless the transmission fluid is warm.
If you haven't done a drain and fill on the transmission that is what I would start with. If you do it twice (with maybe 100 miles of driving in between) you will have 85% fresh fluid after both drain and fills. Even though the system holds about 11 quarts when you drain the transmission sump you will only get about 6 quarts out as the rest is held in the torque converter.
Thanks you BimmerFan32, I guess oil change is better option than mechatronics replacement.
Anyone know what oil to use in transmission for E60's ZF 6HP19 box?
I am not saying changing the fluid will definitely correct your problem but it is a relatively low cost attempt at a solution before digging into the mechantronics unit. Also, unless you know the fluid was changed recently it is definitely time to do this vital preventive maintenance anyway.
ZF Lifeguard 6 is the approved fluid. It can be purchased through a ZF distributor or directly through the dealer.
http://www.thectsc.com/index.php?p=product&id=10&parent=58
I personally use Pentosin ATF1 which is recognized as an OE alternative but if the two fluids were very close in price I would probably recommend the ZF fluid.
Good DIY on changing the fluid.
http://forums.5series.net/topic/88129-diy-zf-6hp19z-transmission-drain-refill/
Transmission oil change was done about 12K ago and this problem started randomly after that oil change and now has become permanent cold start issue. Indy was not reliable, so there could be a link to what you are saying is right. Or atleast that is what I would like to believe, cause I don't like the mechatronics (hate 'em bad).
Was the transmission fluid change done as PM or for another problem? Many shops (including BMW dealers) will reuse the trans fluid if the pan or sealing sleeve were changed due to a leak.
If the ATF was changed for PM do you know if ZF LifeGuard 6 or an equivalent OE fluid were used? If a different non-spec fluid was used that can cause a number of problems.
Have you had any other transmission issues such as slamming, sluggishness or holding gears too long that would suggest other solenoids are having problems?
The mechatronics removal for solenoid replacement is not the end of the world as far as a DIY. It just takes a tremendous amount of time, great patience and a meticulous level of cleanliness. Not even a thread from a towel can find its way into the assembly.
You might see if you can measure the temperature of the trans housing to find out what temperature it is after sitting 10 hours.One more thing, the cold start has to be with the car not turned on for atleast 10-12 hours. If I turn the car on before 10 hours, the error is not visible. Does the time has to do anything with the car being cold or does it points to battery.
I have already checked the battery it is giving 12v in cold when the error happens, does not seems to be the battery.
You might see if you can measure the temperature of the trans housing to find out what temperature it is after sitting 10 hours.
Once I was going to do a drain and fill on the transmission. I ran a short trip and then figured after 6 hours it would be cool enough to work on. No way! Still very hot.
I don't think it is the battery. If you have a charger you might "top off" the battery with a charge before starting it cold to see if that makes a difference.
After some great help from CTSC, I finally figured the solenoid 4E87 is outside the trans above the top of the gear shift. In order to get to it, you have pull out the following in sequence.
1. Hazard switch
2. Panel holding the air vents
3. Front panel containing the controls to AC etc
4. Lower panel where your NAV DVD section.
5. The centre knob
6. Menu switch
7. Gear shift knob + cover + drive panel (which indicate which gear you are in)
8. The complete mid section panel.
9. Cigarette lighter holder
And now finally if you see right above the gear shift, you will see a cable going into the gear shift. That little connector wire is going into the solenoid 4E87 (picture attached). Now back to my problem. During cold start I get a warning for this solenoid not being functional and then it disappears after few minutes. I have checked the solenoid is fine to its resistance of 19-21 Ohms, and the connecting cable has the right voltage during the day time, but strangely at cold start, the cable does not have any voltage at all for few minutes thus causing that fault message.
Does anyone has any idea why the cable will not have voltage for first few minutes? Anyone good with BMW WDS and know where the current in this cable is coming from that I can diagnose further?
Will work on the trans housing temperature. But while I am preparing my mind for the trans oil change myself, I have a question below in case you might know the answer;
1. Is the trans sump has to be changed every time drain/fill is to be performed?
2. While doing a drain/fill, can the filling start at cold (meaning on cold start conditions). Or the trans has to be on a certain temperature to drain it and then on certain temperature to fill it. And then on between 30-40 C to do the second fill with car running.
3. While doing a drain/fill, the second top up has to be done with car running and in Park with handbreak or car turned off after running.