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635CSI Auto Failure

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SKipping View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote SKipping Quote  Post ReplyReply Direct Link To This Post Topic: 635CSI Auto Failure
    Posted: 06 Mar 2013 at 8:35pm

Well today hasn’t been a good one for the Shark.

I've started using her again now it's dried up on the roads, and it's been driving fine. On the way home tonight however things started to come adrift. I kicked down to overtake someone and it didn’t really feel like it had engaged the gears. Odd I though, but maybe it was just a one off and the box had become a little confused. I started to notice a little wobble in the drive from pull away, but again didn’t think too much of it. However as I neared home on a dual carriageway it all went Pete Tong. I was accelerating at a medium rate when it started to feel like the clutch was slipping (To equate it to a manual box). Sure enough if I pressed the accelerator the revs rose, but there was no more shove in the back. Damn!

I cruised on a little more and turned off the dual carriageway which means accelerating up a hill. No real drive.

I came to a stop, stuck the hazards on and turned the car off, thinking maybe the TCU had become confused and needed a quick reset. Nope still no forward drive. Reverse seemed OK, but nothing to speak of in the right direction. It would creep and I managed to let it creep up to a normal road speed and get home.

A quick check on the Internet and it seems the ZF 4HP22′s Achilles heel has been struck with a worn out clutch A pack. I found a particularly good description of my issue here.

There’s also a good deal about how to fix it too with this detailed guide

Just to be sure I went out and checked the car again, no forwards, plenty of reverse, and lots of fluid in the gearbox still. The transmission switch seems to be OK as the lights come on the dash as expected and you can feel it engage reverse or drive, but there’s very little shunt went the drive gear engages. The oil doesn’t smell it’s best so again more evidence that the clutch has gone. Disappointing since the box was rebuilt in 2006, but that was only 18,000 miles ago.

Has anyone else experienced this?

Anyone have any idea of costs to fix this (I'm probably going to have to fix this myself)?

Anybody recommend somewhere that can supply the parts I need for the box?

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AndrewE View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote AndrewE Quote  Post ReplyReply Direct Link To This Post Posted: 13 Mar 2013 at 5:10pm
What year is it?

I ask because a mate has a good used autobox from a 1988 car, a Highline. I think he's after 200 quid - add a couple of new oil seals and a filter, and it works out a cheap fix.

*Now could be a good time to convert it to manual. I've done a couple (well, E28's but much the same) and imo it transforms them.












Edited by AndrewE - 13 Mar 2013 at 6:30pm
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dinkar View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote dinkar Quote  Post ReplyReply Direct Link To This Post Posted: 15 May 2013 at 9:54pm
An achiles heel on a ZF 4HP22 auto box is running the engine on idle for a long time in N or P.  Also reving the engine in N and P is a no no as it kills the auto box. Usually this affects the reverse first rather than in drive.
 
I have had a box ruined like that. I had mine rebuilt about 7 years ago and its fine since. It cost about £700. Mine was rebuilt by Stephens Engineering - http://www.stephensengineering.co.uk/
 
I now try not to run in N or P for longer than necessary. In traffic I now leave it drive with foot brake on if stopped at a traffic light. My MOT test centre after having been told about it do not run the engine longer than necessary during emission test. My local BMW dealer has also told me if I were to inform them at the MOT booking that when the car comes in to do the emission test first and then to turn the engine off.
 
If the engine needs to be run for any engine tests then the rear wheels should be jacked up with handbrake off and in N. This won't damage the auto box.
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gulabh View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote gulabh Quote  Post ReplyReply Direct Link To This Post Posted: 20 Mar 2014 at 2:44pm
do you still do conversion to manual for bmw628csi???
i am not sure if my auto box is non EH!!!!
Smile
how much would i have to pay for conversion??
david

07754828561
silobela47
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beelailydude View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote beelailydude Quote  Post ReplyReply Direct Link To This Post Posted: 22 Mar 2014 at 6:15pm
I had very smilar with my series one Landy V8 i converted to an auto using a 4hp22 box. It turned out to be a blocked filter. Worth a try and they are under £20 plus ya tranny fluid of course. I cut my old filter open and the inside was like a damp hoover bag contents.
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AndrewE View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote AndrewE Quote  Post ReplyReply Direct Link To This Post Posted: 29 Mar 2014 at 12:04pm
Originally posted by gulabh gulabh wrote:

do you still do conversion to manual for bmw628csi???
i am not sure if my auto box is non EH!!!!
Smile
how much would i have to pay for conversion??
david

07754828561


A 628CSi is a non EH box as the engine has Bosch LE Jetronic, not Motronic. With all the bits it works out at around £1200 - actually finding the parts is the hard bit, but it's easier than doing a 635CSi.
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