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#transmissionrebuild

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Nathan Avots-Smith

Day 18: I have a rebuilt, reassembled ZF5HP19 transmission! (Second ZF I've had my nose in this week—does that qualify me for some kind of certification?)

I did use the tool my dad and I made, but not the way I expected to; I used them to support all of the stacked assemblies while I lifted the transmission case up and over them. Hey, it was kind of dumb, but it worked! Next up: prepping the wagon for engine/trans removal. #WeirdCarMastodon #WrenchEveryDay #DIY #BMW #ZF #TransmissionRebuild

On top of the green metal patio table in my backyard, the ZF 5HP19 five-speed automatic transmission from my 2003 BMW 530i stands upright, its bell housing end supported a few inches above the table by two stacks of black rubber blocks. The oil pan and valve body are removed, making it possible to see that all of the clutch packs and gear sets have been installed into the case.
The two stacks of black rubber blocks I used to support the transmission for reassembly on my backyard patio table. On top of each stack of blocks is one of the wooden pieces I had made, intending to clamp them to the input shaft of the last clutch pack assemblies. Instead, I inverted the assemblies and rested the outer rim of the oil pump on the pieces of wood.
The fully reassembled transmission sits on a transmission jack, its newly cleaned and reinstalled oil pan facing up.
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Nathan Avots-Smith

Day 15: I have gone through five of the seven clutch packs (C, B, D, G, and F, with A and E still to do), replacing the O-rings and friction discs, and have cleaned all of the other internals (ring gears and such). I was foiled by a circlip on the D/G drum, so on those clutches I was only able to replace the friction discs, and the A clutch will likely be the same. But all of the O-rings I've removed have been supple, so I'm not too worried about it. #WeirdCarMastodon #TransmissionRebuild #DIY

All of the parts of the F clutch pack from my ZF 5HP19 automatic transmission, separated and arrayed on a table covered by a plastic drop cloth, to dry after being cleaned with mineral spirits.
The O-rings and friction discs removed from and replaced in the F clutch pack of my ZF 5HP19 five-speed automatic transmission.
The D/G drum, containing the reverse gears, from the ZF 5HP19 automatic transmission. The assembly is held together by a metal circlip holding in a spring; I wasn't able to release the circlip to disassemble the drum entirely, so I wasn't able to replace the O-rings.
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