D3 gearbox diagnose / rebuild

[tang0au]

Hi all,

first post, but been lurking here for a while doing research in order to purchase a d3 ...

well, i just purchased an '05 d3 with a couple of small (!) issues that need to be resolved - the price was great as the issues were known about.

1. the gearbox clunks, sometimes ... the change is not smooth - not all the time, but more clunky when feathering the throttle - it will also sometimes rev slightly before engaging first when pulling away - not all the time ..

2. front right lower control arm clunk - not too much of an issue but needs to be resolved.

as part of the purchase we budgeted in a gearbox rebuild / replace of approx 6k, the control arm i can do myself - i centainly dont mind getting dirty with a spanner in hand ...

the gearbox was aparently flushed at 120,000kms, it now has 155,000 on it. the question is if i should try a flush and possibly waste $500 on it, or just do the gbox rebuild.

the next question is can anyone recommend where to get it diagnosed then if required, to do the gbox rebuild in sydney ? either south east syd, or north syd (live in one, work in the other)

Thanks, Barry

[Peter]

Mine has done 150,000km and your symptoms are suggesting more than a flush.

A bit scary as I was hoping to get 200k plus out of the box.

SBL in Brisbane insists I put a replaceable filter on mine next service as a means of preventing premature failure.

You are doing the right thing and getting advice for a trusted repairer.

Sorry I can't help with a Sydney repairer option.

Good Luck.

[SBD4]

You could contact ZF directly. It looks like they do service and repair:

ZF Friedrichshafen AG (http://www.zf.com/corporate/en/products/services/servicecenter/service_network/service-network-location.jsp?id=11494)

[tang0au]

is an option to look at a gearbox from another model ?

according to wiki - ZF 6HP26 transmission - Wikipedia, the free encyclopedia

its in a few fords - and a quick look on ebay turns up a couple of low km box's for only a few thousand ...

?

[Geedublya]

Get a Auto transmission specialist with knowledge of this box to drive it. They will probably want to then remove the pan and check the filter and check for debris. If nothing is found it is likely a flush will fix it.

You could use a transmission from another vehicle except that the ECU for the box is contained inside and the programming is specific to the vehicle. As far as I know no-one has yet been able to flash the ECU and ZF will charge $3K for a new one.

[Rich84]

I've heard of a couple of 6HPs in BMWs and Audis exhibiting this kind of behaviour - turned out they were very low on trans fluid. Your D3 might be the same as banging into gear and flaring is a symptom of this. It is also a symptom of a worn or cracked valve body, but if you're getting multiple symptoms I would take the plunge and do a double flush. You can get the fluid from ebay cheaply - Ravenol brand. About $180 for 20L exc postage. It's made in Germany apparently. Beats paying $70/l from Ford or LR.

Otherwise try a ZF agent for the Lifeguard6 fluid as it will be about 1/2 the price of getting it from LR.

From what I've read the 6HP is generally a pretty reliable box, with the torque converter clutch being the weakest point. That said the LR party line of "sealed for life" is rubbish - the box definitely needs routine servicing.

[tang0au]

thanks guys ... spoke to a couple of specialists in sydney - $7k for drive in drive out replacement box ...
deffo want to ensure the vehicle lasts another 100,000 so may just take the plunge ... but will check out fluid levels etc first ... take delivery in a couple of days.

[Nomad9]

Hi tang0au,
Make sure the gearbox is at the right temperature when you check the level.

[Rich84]

Correct - fluid temp must be between 35 and 40 and the engine must be running at idle with the A/C on when you do the level check.

[sheerluck]

...... You can get the fluid from ebay cheaply - Ravenol brand. About $180 for 20L exc postage. It's made in Germany apparently. Beats paying $70/l from Ford or LR.........

Rich,

I can't find that on ebay anywhere that's prepared to ship to Aus, and according to Ravenol's website (http://www.ravenol.de/en/unternehmen/weltweit.html) they have no presence in Aus. Their websiete does state that it has been tested in the 6HP26, but I can't find anywhere that it is approved by ZF.

[Rich84]

They aren't and in fact no other fluid is - Lifeguard6 is the only fluid that is approved by ZF and all the other brands sold by the various manufacturers are just repackaged LG6. Which itself I believe is manufactured by Shell (and sold by them too - under a different name - which is also not approved by ZF). Either way, if this fluid is designed to work with a ZF box, it'd be worth trying it if you're looking at a $7K replacement trans bill anyway.

I haven't made the enquiries myself, but the ebay page says it "Ships to Worldwide" for the Ravenol fluid.

I bought my fluid from a Ford dealer and even when I screwed him on price it still cost $45 per litre. Next time I will be buying a 20L drum from ZF - think it's under $500 for this. This is unless I can get something from Ravenol.