I did it - rebuilt a 5hp24

[BennyM]

Even after all these great pictures, I still have no idea how a transmission works.

Color me impressed!

[shogun]

http://www.jagrepair.com/images/Auto...r%20Manual.pdf
BMW/JAGUAR ZF5HP24
“A” CLUTCH DRUM FAILURE

Complaint:
A vehicle with a ZF5HP24 comes in with a complaint of little or no movement forward,reverse is good.
Upon disassembly of the transmission the “A” Clutch drum is found to be broken at the clutch pack retaining snap ring (Refer to Figure 1) and the snap ring has come out of the drum.
The technician replaced the drum with the updated part only to have it come back with the same complaint and the same broken drum.

Cause:
The drum is breaking in the snap ring area due to un-commanded pressure spikes. There is an updated pressure regulator valve (See Figure 2) which could help the situation as long as the valve bore is not worn. The pressure spikes can still occur and are caused by wear in the pressure regulator valve bore in the lower front valve body, Refer to Figure 3.

Correction:
Using the part numbers found under Service Information, replace the pressure regulator valve and the lower front valve body.

Service Information:
Updated “A” Clutch Drum.................................1058-270-040
Updated Pressure Regulator Valve.....................1058-327-030
Lower Front Valve Body...................................1058-327-022

http://jagrepair.com/images/AutoRepa...0ZF5HP24-1.pdf

Oversized Pressure Regulator Valve Kit
Symptoms: •B Clutch breakage
•Delayed Reverse
•Erratic line pressure
•No Reverse
•Poor shift quality

Cause: Excessive valve and bore clearance due to wear


Correction: The Sonnax oversized valve kit restores correct valve-to-bore clearances and circuit integrity as well as preventing future wear in this area.


139740-01K
•Valve
•Spring





























Wear is commonly found at different areas in the ZF5HP24 pressure regulator valve bore. Wear at the inner portion of the bore causes high pressure spikes leading to broken drums, pistons or other parts, as well as restricting converter/lubrication flow. Wear at the spring end of the bore allows line pressure to exhaust resulting in low line pressure, soft shifts and burnt clutches. The Sonnax oversized pressure regulator valve kit 139740-01K restores valve-to-bore clearances so the pressure regulator valve can maintain correct pressures.
•Annular oil grooves support the valve and reduce wear rate.
•Restores valve-to-bore clearances maintaining correct pressures.

http://www.sonnax.com/parts/1767

http://www.sonnax.com/resources

[bimmer nut]

BTW, Since this old thread was revived, I went ahead and fixed the slide show of the rebuild I did on that first post baxk in 2009 - http://bimmernut.com/5hp24show/

Hey, that tranny is still running fine. 200k+ miles!

[Rustam]

BTW, Since this old thread was revived, I went ahead and fixed the slide show of the rebuild I did on that first post baxk in 2009 - http://bimmernut.com/5hp24show/

Hey, that tranny is still running fine. 200k+ miles!

Haven't looked at this yet, although did try to earlier, thank you for the update. Also two questions -

Did you use any formal guides on the disassembly and examination procedure?
What guides did you use for the dissasembly and examination procedure?

[bimmer nut]

Haven't looked at this yet, although did try to earlier, thank you for the update. Also two questions -

Did you use any formal guides on the disassembly and examination procedure?
What guides did you use for the dissasembly and examination procedure?

I used no formal guides. I looked at three different documented DIY jobs posted up on the Internet. It's been 5 years, prolly better ones out there by now, and besides, I don't have those links anymore. Sorry - but just now I did a quick google search (on "5hp24 rebuild") and there looks like there are some good ones out there.

[shogun]

Repair manuals for $20 http://www.autoepcs.com/zf-service-repair-c-27_117.html

Here are also good pics inside, E39 5HP18 valve body repair http://forum.roadfly.com/threads/131...aul-DIY-Part-1

[Rustam]

I used no formal guides. I looked at three different documented DIY jobs posted up on the Internet. It's been 5 years, prolly better ones out there by now, and besides, I don't have those links anymore. Sorry - but just now I did a quick google search (on "5hp24 rebuild") and there looks like there are some good ones out there.

Thank you for the help

[Rustam]

Thank you, Shogun.