The fix may be as simple as lubricating the gearshift cable clamp bolt which sometimes becomes so corroded that it will no longer articulate in the hole in the selector lever (necessary because the cable moves linearly and the lever through an arc). This causes the gear lever position and the...

The transfer box bearings are certainly a possibility: http://www.fullfatrr.com/forum/topic12404.html Phil

Okay Pete, I look forward to hearing from you. With the friction plates, you can buy a complete aftermarket set, like these Exedy ones at £77 : https://www.ebay.co.uk/itm/Audi-BMW-5HP24-Automatic-Gearbox-Friction-Kit-Exedy-/192110410573?hash=item2cbaac3b4d By the way, the A & C plates are...

The D brake for the Range Rover variant of the 5HP24 has four friction plates. There are quite a large number of heat spots on the ones from Pete’s transmission and that isn’t uncommon. This brake is the most susceptible to overheating in the 5HP24 and on higher torque variants i.e. the BMW E53...

The B & C clutches next. Pete’s B clutch pack has a single heat spot on the inner half of the steel plate facings, which is very common. The friction plates show heat glazing in the area corresponding with this. The C clutch pack is in perfect condition. The C clutch is only...

Pete and I decided that it might be best if he left the six clutch assemblies with me for dismantling, as I have the special tools to compress the springs using a mandrel press. Pete will, of course, be rebuilding the transmission himself. I usually just work through each of the clutches in...

Pete, I’m pleased to say that none of the remaining screws put up much of a fight. Phil

Phil

Pete, just wondered how you were getting on with removing the F-brake drum screws? I’ve just started stripping another transmission so I quickly filmed the screw removal with my phone (sorry about the quality). Firstly, using an air impact wrench : (easy huh?) and secondly with hand tools ...

If you’re after further entertainment once it’s stripped down, Pete, I can strongly recommend working out which part of the hydraulic circuit is fed by each worm track in the valve body assembly, and the function of every restrictor/orifice in the duct plate sheet. It’s difficult to imagine what...

Pete, The screws have a standard right-hand thread. In my posts on stripping the 5HP24 (e.g. http://www.fullfatrr.com/forum/post319415.html#319415) I recommend undoing these countersunk screws first, while all the weight of the transmission is still in it, and striking the screw heads a couple...

All looking good so far, Pete. I suspect the pitting marks are just porosity in the casing that’s been exposed when it was machined. Aren’t all 666 components in the 5HP24 an absolute joy to behold? Phil

If both 4th and 5th gears are slipping, as the codes suggest, it may well be an issue with the direct clutch possibly related to the infamous ‘toilet roll shaft’ failure, which transmits drive from the direct clutch hub to the epicyclic carrier Phil

Pete, You’d be very welcome to chuck your casings in my parts washer when you come back to get the clutch pistons removed. Phil

Goes without saying that all trainee 5HP24 rebuilders are required to generate a full measurement report for the clutch packs, bushes and end floats. I look forward to seeing it, Pete. Phil

Unfortunately, I don’t have any 260mm F38 converters in stock at the moment, only the 280mm L51 for the 4.6 M62 engine. More often than not the re-manufacturer doesn’t keep a stock of them either and they rely on rebuilding the actual unit that you send to them which they then return to you. I...

Your transmission came off the production line at Saarbrücken on 11th January 2004 so it has all the final upgrades including the ‘350’ valve body assembly and the ‘967’ F-brake piston. I have all the parts you need for the rebuild in stock. If you’d like me to put a quotation together just...

When the transmission was launched back in 1996 the only fluid authorised for the 5HP24 was Esso LT 71141. Exxon-Mobil subsequently re-branded this fluid as Mobil ATF LT 71141. ZF then decided it made commercial sense to start selling fluids badged under their own name so they got Pentosin in...

It’s just worn. The total movement of the LUC piston from fully on to fully off is only around 1 mm so it doesn’t take much wear in the friction plate for the problem to start. I drove mine for several thousand miles in this condition and when I eventually replaced it the friction plate looked...

I have very little personal experience of using K Motors but I haven’t heard any bad things about them. They used to re-manufacture their own transmissions but I don’t think they do any more. I know their parts division (LRDirect) is the main part of the business now, but the garage has been...