L322 Oh no it's another gearbox on a 4.4 petrol zf gearbox 2003

Had this rangie since Jan. Has been running fine and has a fine very expensive history and has done 82k miles now all documented service history In 2010 on its way to Switzerland the gear box went and I have the bill for 5500 euros ouch !!! New box cooler and torque converter. That was 30 k miles ago
On the way to the coast this week it came up with the failsafe message and stuck in 4 th
Code reader at the ready it was P0763 and said shift solenoid c
Anyway I carried on and it got me to the coast in 4 th
After 6 hours of leaving it it ran like normal no codes and I got to the hotel 3 miles away with lots of hills and stops. Again in the morning no problems until I hit the m25 and failsafe mode and 4 th all the way home
Now at home I've decided to give it an oil change. Started her up and said transfer box neutral
Took it round the block and that fault disappeared and the box was how it should be
It's now on jacks with the gearbox sump off
There was plenty of oil about 5-6 litres but was dark and thin. Nothing in the sump, just very fine coating and the magnets had nothing that would worry me
I'm waiting for the oil to be delivered as the filter has been changed and a new gasket fitted. Any ideas or just that it probably needed new oil
No judder but before this reverse has been hit and miss , but forward is super smooth no judder or surges
To top the day off the gas started playing up and had to go all the way on the gold stuff
Came back all the way on gas
The Mrs was not too pleased at all

I advise buy her some chocks and flowers.

You should certainly eliminate low battery voltage and a faulty transfer box shift motor potentiometer as possible causes before moving on to consider possible transmission faults.

You need to check that you’re getting 13.5V to 14V across the battery terminals at tickover and that you can select low range on the transfer box and then get back into high range again.

If it is an issue with shift solenoid 3 then that may explain your problems with selecting reverse. This solenoid’s only function in life is to activate the reverse gear protection valve (RG-V) in the event of the driver accidentally moving the shift lever into reverse while travelling forward at speed.



Phil

Thanks Phil. I have you stored in my contacts if it's a pull and mend job
Yes it may be the battery or alternator
I regularly check the volts out and it as it should be and the battery was New at the start of the year
I will check again if it is around the 14 v on load
This may explain the gas dropping out, but the gas was ok all the way home
I had to put it in low ratio to get it up the ramps so I could get under the beast. No problems doing this and had to do it a couple of times

I've also taken off multi plug and put back as all the terminals looked ok on the gearbox
It won't hurt to change the oil as you never know what those frenchies put in it

Just got heads up the oils been delivered. Will be in touch after I've filled it

Ok filled her up and shifted the gear lever forward back and in the manual selection then waited to warm up and filled her to the top
Test drive
First impressions very smooth no problems. But then the trans safe mode came back in
Took her home sat on drive for 1/2 hour after clearing fault with diagnostics
Which said solenoid c
Set off again this time in manual and no problems up and down the box but then cam up with trans safe again
I'm thinking it looks like a solenoid problem. Any thoughts ?

Might be worth testing its winding resistance at the 16-pin connector (between pins 4 & 16). Should be around 26-27 ̕Ω. The fault could also be with the internal wiring loom (solenoid faults are fairly unusual in the 5HP24).







Or you may find it easier to check the winding resistance at the ECU end in the E-box under the bonnet (between wires 16 & 21 of the C1835 connector)









Shift solenoids cost £76 and a new wiring loom £89



Phil

Phil many many thanks
Plugged in the data reader to see anything on the next trip out when it had cooled and not showing fault. Nothing I could see as my reader is not that good but it was showing valve 3 always off whilst the other 2 changed from on off as I was manually changing gear
I went underneath again and pulled the electrical connector on off a few times to eliminate that. Also took a picture of the zf ref plate so I can get the proper spares when needed
As the connector is so enclosed at the gearbox i went into the ecu box and measured the resistance as shown above
It was open circuit. Turned the ignition on it was still showing trans failsafe at this point
Are we getting their Phil or is it a mystery

Did you take the resistance measurement with the connector removed from the ECU?
Phil
P.S. All 4.4 V8 M62-engined Range Rovers used the 1058 000 032 model of the 5HP24, but if you let me have the transmission's serial number I can let you know the date of manufacture and whether it had all the later modifications from the factory

It was taken with it off the ecu
Serial number 0483086
Model number 000032
I e sent you a pm Phil about another matter

Those pins are tiny so might try again tomorrow if I get chance. My eldest gets his gcse tomorrow

Your transmission came off the production line at Saarbrucken on 8th September 2002 so it was manufactured to the final specification, including all the modifications/upgrades. Hope all goes well tomorrow. I'm off to Malta tomorrow for a week so I may not be able to respond for a while.
Phil

Happy Maltese break
Tell you how it's gone when you get back

Bemble said:

Your transmission came off the production line at Saarbrucken on 8th September 2002 so it was manufactured to the final specification, including all the modifications/upgrades. Hope all goes well tomorrow. I'm off to Malta tomorrow for a week so I may not be able to respond for a while.
Phil

Click to expand...

Have a good holiday

What a job trying to get hold of one of those solenoids. You need the full plate info on the side of the box and then it's not clear as zf don't describe them as shift solenoids
Anyway got one for around the £70 mark. Would have got one from Phil but as above he's in Malta
He needs a medal that man
Looks like another drain and pain this weekend

Willos said:

What a job trying to get hold of one of those solenoids. You need the full plate info on the side of the box and then it's not clear as zf don't describe them as shift solenoids
Anyway got one for around the £70 mark. Would have got one from Phil but as above he's in Malta
He needs a medal that man
Looks like another drain and pain this weekend

Click to expand...

Good luck. Hope it curesit. Fascinating thread. Bemble is an absolute marvel.

Dropped the sump this morning Again nothing to be alarmed at
9x T27 bolts hols the plate that holds the solenoids
These are a pain to get out as the oil is so slippy and its tight at the rear of the box
The plate comes off no tight fit so you can pull any solenoid
Pull solenoid c or mv3 on Phils photo
Replaced with new one and then replace the plate and the screws. What a pain they are as everything is wet with oil
All went back together fine
I would advise replacing screws as T 27 are a little small for what it holds up
ATF back in (Mobil)
The test drive was fine and did around 40 miles to make sure
Yerrrr no codes so I'm crossing my fingers it's ok
The pulled solenoid had the correct resistance but obviously the internals were fuched So fingers crossed as I'm going to fill her up with gas and then 185 mile journey tomorrow

Well alls well. Was a faulty solenoid. The box is working very smooth and no codes. Thanks Phil for all your help

Well now 650 miles on and no problems with the box. Just a faulty solenoid. It gave the correct resistance reading across the terminals, but the internals were obviously faulty. .
Moral of the story is to get a good enough code reader that reads gearbox codes not just the engine. You can swap solenoids around to see if its that one but you have to put the sump back and fill again with oil.
I did have a code reader that read box codes and cost just over £100 and does SRS and ABS. If you dont have one and go to a garage i could have forked out between £420 and £3000. My local indy wanted £420 for a flush with nothing else.
The solenoid was £75 next day delivery plus the new oil, plus filters and gaskets at market price.
Not everyone is going to get away with as little as that but at least your for warned with info before a garage treats you like a cash cow
Phil is a star with the ZFgearbox and if the box gave up id go to him first although hes over 200 miles away.