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Discussion Starter · #1 · (Edited)
ZF 5HP19 Facts, Documents, troubleshooting

Hi,
Starting a new thread dedicated to the ZF 5HP19 Automatic transmission. This thread hopefully consists of facts, ZF documents and troubleshooting tips that are based upon these documents or other ZF documents.

I'd like to see posts that discuss a problem and a report of steps taken to resolve that problem with success.

This way we don't pollute this thread with " it's broken, how do I fix it". Let's try to keep those topics on a different thread.

Thanks! /Dave
 

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Discussion Starter · #3 ·
ZF technical details, theory of operation, solenoids, etc

ZF technical details, theory of operation, solenoids, etc. I found this very helpful in understanding how the shift and TCC solenoids operate and how to troubleshoot a defective solenoid.
 

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Discussion Starter · #4 ·
ZF spare parts catalog and filling charts

This is a short document that is especially helpful in understanding how to properly fill your transmission. NOTE: The importance of determining the fluid temperature for proper filling.
To get vehicle level, I jack up the front, put jack stands under the front pads, then jacked up the rear. I then measured from the floor to the front pads, then used that measurement to set the height in the rear.
 

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Thanks!
 

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Discussion Starter · #6 ·
Si 24 03 06

This Service Information bulletin supersedes SI 24 03 06 dated February 2008.

designates changes to this revision

SUBJECT
ZF 5HP19 Transmission - Diagnosis of EGS FC 048 (30 hex)

MODEL
E46: 323i, 325i, 330i with M52TU, M54, M56 and ZF 5HP19

E39: 525i, 530i with M54 and ZF 5HP19

E85: Z4 roadster 2.5, 3.0 with M54 and ZF 5HP19

SITUATION
"Service Engine Soon" is illuminated and fault code 048 "Converter lock-up excessive slip" (30 hex or P0741) is stored in the EGS transmission control module.

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.

[S2406U01.JPG]
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.

Additionally, if the transmission fluid shows signs of deterioration ("dirty fluid"), the fluid should be replaced in conjunction with the fluid strainer. For the strainer replacement procedure, refer to Repair Manual RA24 31 151.

Refill and/or top off the fluid level according to Repair Manual RA 00 11 500, using ESSO ATF LT 71141 (P/N 83 22 9 407 807).

If after careful inspection it appears that the turbine seal is intact, contact Automatic Transmission Enhanced Technical Support (TeileClearing) for further diagnostic instructions. Submit the "regular technical support" PuMA case, referencing SI B24 03 06 in its title.

WARRANTY INFORMATION
Covered under the terms of the BMW New Vehicle Limited Warranty.

Please refer to the latest KSD for the appropriate model applicable labor allowances.

Defect Code
24 40 02 61 00

Labor Operation
24 40 002
Main Work*

Replace torque converter

or

Labor Operation
+24 40 502
Replace torque converter

*Main Work:
Use this labor operation number when this is the only repair being performed, or if this is the main repair when performed along with other repairs at the same time. If this is not the main repair, refer to KSD for the associated (+) labor operation code.
 

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Found new TC reseller...$255+ s/h

So after 150 miles after the "re-learn" drive cycle the SE light came back again and sure enough code P0741 re-appeared. So the TC replacement will be the next option. Still don't feel any shifting problems nor any degrading of fuel consumption (avg 27-28 miles per gallon hwy).

My tech pulled through yet again today and found a company that specializes only in Torque converters and they are located in Southern California. For a new TC they only charge $255 + $20 s/h....and no core return required. And they offer a 1 YEAR LIMITED WARRANTY ON THEIR PRODUCT!!!:thumbup:

So anyone in need go to: www.torqueconverter1.com

Will probably do the repair in a week or 2 just in case there are some underlying issues going on with the TC/tranny.
 

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So after 150 miles after the "re-learn" drive cycle the SE light came back again and sure enough code P0741 re-appeared. So the TC replacement will be the next option. Still don't feel any shifting problems nor any degrading of fuel consumption (avg 27-28 miles per gallon hwy).

My tech pulled through yet again today and found a company that specializes only in Torque converters and they are located in Southern California. For a new TC they only charge $255 + $20 s/h....and no core return required. And they offer a 1 YEAR LIMITED WARRANTY ON THEIR PRODUCT!!!:thumbup:

So anyone in need go to: www.torqueconverter1.com

Will probably do the repair in a week or 2 just in case there are some underlying issues going on with the TC/tranny.
Did you ever replace your TC? I'm waiting for a Bavarian Technic software kit to diagnose what codes mine is throwing but could be transmission related, my alternator crapped out and kicked in TRANS SAFE MODE. Replaced the alternator within 7 miles of incident so hoping did no permanent damage... did make a good loud CLUNK when it happened as I was doing 80 mph on the highway at the time the battery light came on : (
 

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HELP PLEASE ! fault code 048 "Converter lock-up excessive slip"

Hi, i just saw your post on the fault code 048 "Converter lock-up excessive slip" (30 hex or P0741), i have this trouble since 2 week, i have the transmission light in the dash each 1-2 days, the tranny run very well do you think that is a torque converter problem, because each shop want to rebuilt the entire tranny.

Thanks:
 

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Hi, i just saw your post on the fault code 048 "Converter lock-up excessive slip" (30 hex or P0741), i have this trouble since 2 week, i have the transmission light in the dash each 1-2 days, the tranny run very well do you think that is a torque converter problem, because each shop want to rebuilt the entire tranny.

Thanks:
My alternator crapped out and then was replaced with the battery disconnected. The BMW dealer told me that a battery disconnect after a TRANS SAFE MODE (kicked on due to low battery voltage) can scramble the transmission module code. 4/2 I go in for a $118 reflash. If I drive it a week without the SES light coming on, I'll change the ATF and filter ($325 at the stealer). If it does come on when they do their test drive, I'll change the ATF and filter too.

A torque converter is $150 + $20 shipping from a CA company. If it bugs me, I'll have the TC changed and see what happens from there. I cant see any reason the mechanical part of the tranny / gears / clutches / etc will go bad due to a TC... I'll post my results.
 

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Hi, i just saw your post on the fault code 048 "Converter lock-up excessive slip" (30 hex or P0741), i have this trouble since 2 week, i have the transmission light in the dash each 1-2 days, the tranny run very well do you think that is a torque converter problem, because each shop want to rebuilt the entire tranny.

Thanks:
Did you ever solve your issue? I cant believe it is my TC seal as it takes 170 miles before it comes back on... thinking if it was a torn TC seal it would come on right away... this is with me pushing it hard right after resetting. Seems with so many electrical "nuances" I'm fearful of doing the TC replacement and not fixing anything. I had the EGS reflashed at my BMW dealer $118, now thinking do an ATF flush / filter and see what it does... last resort will be a TC.
 

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Ok, just had the most informative conversation with a ZF authorized BMW repair facility out there in CA, Dose BMW 619-322-3065, www.dosebmw.com. Steve Dose knows his ZF stuff... bottom line, likely the TC seal is torn, apparently very common on our trannys. Also, the impact of not repairing it right away is that the torque converter may not lock up at highway speed which in my case means rpm's of 2900 at 80mph vs. 2750 (slightly worse gas mileage). He thought my trans safe mode / alternator event was a coincidence vs. the cause of the code 48. Also said that ESSO is now TrueLife and that Valvoline MaxLife $5 is just as good, he uses TrueLife only becuase using MaxLife (red) can confuse the uninitiated and they can make the mistake of putting in regular ATF. He also clarified the "no flush" theory is bunk, old tranny's used to varnish up which some believe can "hold together" an older transmission. For mine, under 65,000, the fluid is likely fine but if I wanted to flush it, I could (I'm secretly hoping that will eliminate the code 48 by some magical means). Otherwise, his suggestion, new TC, they sell ZF rebuilt ones for $475. He said check on the cheaper $200 units you hear about and make sure they are actually rebuilt by those that know and have the replacement parts to fix them. So my plan is RedLine in the engine, Valvoline MaxLife in the transmission and RedLine in the rear diff. Hope this info helps anybody searching on this issue / code.
 

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Discussion Starter · #20 ·
Ok, just had the most informative conversation with a ZF authorized BMW repair facility out there in CA, Dose BMW 619-322-3065, www.dosebmw.com. Steve Dose knows his ZF stuff... bottom line, likely the TC seal is torn, apparently very common on our trannys. Also, the impact of not repairing it right away is that the torque converter may not lock up at highway speed which in my case means rpm's of 2900 at 80mph vs. 2750 (slightly worse gas mileage). He thought my trans safe mode / alternator event was a coincidence vs. the cause of the code 48. Also said that ESSO is now TrueLife and that Valvoline MaxLife $5 is just as good, he uses TrueLife only becuase using MaxLife (red) can confuse the uninitiated and they can make the mistake of putting in regular ATF. He also clarified the "no flush" theory is bunk, old tranny's used to varnish up which some believe can "hold together" an older transmission. For mine, under 65,000, the fluid is likely fine but if I wanted to flush it, I could (I'm secretly hoping that will eliminate the code 48 by some magical means). Otherwise, his suggestion, new TC, they sell ZF rebuilt ones for $475. He said check on the cheaper $200 units you hear about and make sure they are actually rebuilt by those that know and have the replacement parts to fix them. So my plan is RedLine in the engine, Valvoline MaxLife in the transmission and RedLine in the rear diff. Hope this info helps anybody searching on this issue / code.
So did he discuss if the new TC seal is of a new design to prevent this from happening again? Seems to be a common defect. If this was not discussed, can you ask him and post the answer please.

Also be aware that if the TC is slipping, then the friction materials are slipping, heating up, which result in fine burnt particles in your fluid. At some point, the friction material is worn away and metal is removed.
 
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