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Tom Ballard

Looks to be an end to an era :( 535d gearbox issues

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So, my 2004 535d has refused to hit the 200k miles mark.

 

Everything has been running like a dream. I had the gearbox serviced for a 2nd time in 3 years in March. Been really looking after the car and chipping away at small defects and had planned to keep the beast much, much longer....but no.

 

Driving to go get my hair cut on Monday and it accelerates up into 3rd and as it tries to shift into 4th, the box slips and sends dreaded gearbox fault on the dash.

 

I call the AA and I’m basically telling him what’s wrong with it, he was clueless. They follow me Home with the orange beacons on, fortunately I was only 4 miles away from my home.

 

I have taken it out again after clearing the fault and the same happens again. Parked up on the drive now, I haven’t even bothered looking for a GB specialist to fix it...I’ve seen the nightmare ££ signs on other forums.

 

This has all come out of nowhere. Literally just removed the EGR and cooler etc as it was leaking back into the exhaust. And whilst I was there I renewed the main stat... I’ve spent far too much money on this hobby and as much as I truly love the car, it’s time for a new one.

 

Going to look at an Audi Q7 4.2 today. Absolutely gutted!!!!

 

Anyone interested in the 535? What’s it worth in this condition?

 

 

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That's really bad news especially as you say you love the car. You could try Automatic Transmissions in Preston for a chat and estimate but that may not suit geographically or financially and if you've had enough you've had enough.

They are on 01772-259068 if you do decide to get a cost for repair.

Good luck.

 

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It really makes me think, gearbox services are they best left alone? ive heard pro's and cons of each and really starting to question at high miles is it worth servicing box atall??? hmmmm

 

 

Gutting about the car! not worth buying a second hand box and throwing that in ?

 

 

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i'm still at a loss as to wether to do mine or not

 

you see ppl who like yourself service it and it breaks and you see ppl who dont and it breaks. 

 

 

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^You are dammed if you do and dammed if you don't.

 

The failures are rare but sadly when they do happen to the oldest E60's it's not financially worth repairing.  Hence F10 ownership and loss of a bellowing V8 :(

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I'd probably speak to a couple of specialists and see what the options are.

 

Obviously with the car near 200k then its value is low so spending big will probably not make financial sense in terms of resale so its a "spares or repairs" sale but then that said how much do you need to find to replace it?

 

I've just spent £500 on some paint for my e39 - car might be worth £3-4k tops and i've spent half that over the 3 years i've had it so lets say its cost me £7k in three years but that £7k still wouldn't have got me anything much better and i havent had to find it in a lump.

 

What am i saying? I suppose if everything else is good, is a recon box not the silliest idea and cheaper than a new car especially if the intention was to run it for a good while.

 

 

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3 hours ago, kjb1 said:

It really makes me think, gearbox services are they best left alone?

 

 

Yes I've been wondering too. I've had mine done once, 4 years ago at 105k miles. Now 139k miles. I'm pretty sure I'm not going to get it done again. Only if it starts losing oil due to the common leak with the connector. It will last as long as it lasts.

 

Certainly twice in 3 years in the case above is pretty frequent, although not sure how many miles the OP is doing.

Edited by Tuvoc

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Unfortunately servicing your gearbox is like servicing your engine. Just because you give it oil changes every 10,000 miles doesn't mean it's not going to throw a rod out the block when you floor it one day, it's just the luck of the draw. If the car is in good condition and does everything you need it to well and you actually like it, why not look at a recon box? A recon box and maybe torque converter (be rude not to do it whilst in there) must surely be cheaper than replacing the car?

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If you've spent a lot of time, money and effort getting the rest of the car spot on, it might be worth pricing up your options?

 

 

 

 

Especially if the alternative is a Q7. :D

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id be tempted with recon box or the like. Certainly not end of the world for the car

 

 

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There's mechanical wear on other parts such as the engine and diff.

 

Here's a chap who bought his car new (E60 2005 535D) and reached 300K milestone :

 

Hello all,

 

This may be of interest to long standing E60 diesel owners. I purchased this car new in March 2005 and it has never broken down or failed to start. It has oil/filter changes every 6K done at home and generally filters and fluids are changed at roughly half intervals.


The car is driven using the torque rather than revving, it rarely sees in excess of 2000rpm. It has been extraordinarily reliable, the first items replaced being a coked anti shudder throttle valve and EGR thermostat at 160K, nothing else has been done to the engine other than replacing a lazy starter motor at about 200K. Transmission oil and sump filter changed regularly, slipping torque converter replaced at 260K, box still changes smoothly with zero backlash.
 

Remarkably, the DPF is original (car asked for change at 136K) and the car has never flagged a warning light although I will have back pressure checked at next MOT (must be ashed up by now). All fuel related and turbo equipment is original and untouched.


Dampers replaced at about 220K and anti roll bar rubbers and two lower rear suspension bushes. A corroded rear brake pipe (mild steel amazingly) running between subframe body was a long and expensive repair. This is an honest appraisal of work done to now and reliability is no doubt down to its diet of long motorway/dual carriageway journeys and little stop and start, min journey lengths around 10 mies. The front discs are original (not knackered) and the car only on its second set of pads with loads of mileage to go. Replaced light blue DDE relay a month ago stopping a spate of warning lights. Even all the bulbs are original other than the front "angel eyes" bulbs


I bought this car with the intention of it being my last and look forward to many more years with the beast. I do not hang around and the car keeps up with the traffic.

Edited by jake13

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I didn't repair mind because I figured it was £3k I could put towards the next car. 

 

I would have paid to repair it but after listening to the wife, sensible head won the day.:(

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@Tom Ballard

 

Just rereading your first post

 

Did you retrieve a fault code?

 

It might not be all doom and gloom, it could be a simple fix and the twin turbo beast lives another day to scare Porker drivers. Depends on what the fault code is.

 

There is little point putting a box from a breaker in it due to unknown condition of the box. A refurbed box swapped in and out is the best bet but that will cost £2500-£3200. Trade in value, realistically not much more than that being brutally honest.

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3 hours ago, 535i Andrew said:

I didn't repair mind because I figured it was £3k I could put towards the next car. 

 

I would have paid to repair it but after listening to the wife, sensible head won the day.:(

The what happens if in a few months the replacement car goes tits up.. If everything else on 5er is good I'd get the gearbox fixed and you'll get another 200k out of it

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4 hours ago, Blobby said:

The what happens if in a few months the replacement car goes tits up.. If everything else on 5er is good I'd get the gearbox fixed and you'll get another 200k out of it

 

Good point Sir,

 

New car under AUC warranty.

 

Outgoing E60, due to it having an N62, had lots of oil leaks to fix inc the dreaded alternator bracket leak, 4 camshaft sensors needing replacing, a secondary air system fault and something on the IBS system showing a code......but not affecting anything at the time.

 

I needed the reliability at the time as I'm needed for nursery pick ups so after many many tears, decision was made.

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Hey all,

 

I’ve gone out and bought myself an Audi Q7. I actually love it! Just missing the pure power of the 535.

 

I read and reset the fault codes and they keep returning as soon as the Box tries to shift into 4th. First 3 gears pull like a train still!

 

I can’t remember the codes right now, but I remember it stating it was an unknown transmission fault on Carly. I’ll have a look later and upload.

 

So the car is sat on the back drive, still gutted but I’m pretty excited about my q7 right now. Still get the lump in the gut when I go into my conservatory and see the beast sat there though.

 

Think I’m going to clean her up and put it up for a genuine sale. ‘Sigh’

 

 

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7 hours ago, Tom Ballard said:

Hey all,

 

I’ve gone out and bought myself an Audi Q7. I actually love it! Just missing the pure power of the 535.

 

I read and reset the fault codes and they keep returning as soon as the Box tries to shift into 4th. First 3 gears pull like a train still!

 

I can’t remember the codes right now, but I remember it stating it was an unknown transmission fault on Carly. I’ll have a look later and upload.

 

So the car is sat on the back drive, still gutted but I’m pretty excited about my q7 right now. Still get the lump in the gut when I go into my conservatory and see the beast sat there though.

 

Think I’m going to clean her up and put it up for a genuine sale. ‘Sigh’

 

 

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There's nothing wrong with a Q7. I used one for work a few weeks ago just to move some stuff in. For sheer load lugging capacity and a do ANYTHING ability (including off road if you put proper 4x4 tyres on it) I really don't think they can be beaten. I'm seriously considering either a Q7 or a Touareg as a next car. 

Edited by Mashed Potatoes

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There's nothing wrong with a Q7. I used one for work a few weeks ago just to move some stuff in. For sheer load lugging capacity and a do ANYTHING ability (including off road if you put proper x4x tyres on it) I really don't think they can be beaten. I'm seriously considering either a Q7 or a Touareg as a next car. 

 

It’s one hell of a car mate! Mine has every optional extra you can imagine!

 

I got into my 5er earlier today to shift it down the drive and it just made me love the Q7 more. I thought the E60 was a nice place to sit, but the Q7 is out of its league. Everything I need to do the 500 mile round trip from Scunthorpe to Portsmouth to get my children once a month.

 

 

 

 

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Could be simple as broken bridge seal to worn pump bushing.

 

Interesting, I just jumped to the conclusion that it was knackered. It did just come out of nowhere though?

 

What sort of costs would I be looking at for repairing it if it were that?

 

It still drives perfectly fine, just goes into fault when trying to change into 4th and then it remains in 3rd till you turn off and on again....

 

I’d love to get it fixed up and sell it on for someone else to enjoy. I’m more than confident it’s got plenty of juice left in the straight 6 and turbos (both reconditioned just before I got it) I’ve spent a fortune on Maintenance, both reactive and preventive. So would be a shame to strip down for parts or sell on the cheap

 

 

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1 minute ago, Tom Ballard said:

 

It’s one hell of a car mate! Mine has every optional extra you can imagine!

 

I got into my 5er earlier today to shift it down the drive and it just made me love the Q7 more. I thought the E60 was a nice place to sit, but the Q7 is out of its league. Everything I need to do the 500 mile round trip from Scunthorpe to Portsmouth to get my children once a month.

 

 

 

 

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I agree with you. For sheer straight line speed (unless you've bought the V12 diesel!) the 5er will have it no problem. Same as throwing it round corners obviously. Quiet, really comfy but doesn't really wallow too much I found, and feels as well if not better screwed together than the E60 does. People label them as crap with the Chelsea tractor image, which is unfair. Get in one and live with it for a bit then you might see why they're so good.

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I agree with you. For sheer straight line speed (unless you've bought the V12 diesel!) the 5er will have it no problem. Same as throwing it round corners obviously. Quiet, really comfy but doesn't really wallow too much I found, and feels as well if not better screwed together than the E60 does. People label them as crap with the Chelsea tractor image, which is unfair. Get in one and live with it for a bit then you might see why they're so good.

 

And I was one of those who called it a Chelsea tractor! But i saw one on the forecourt and sat in it, felt the quality instantly...decided on a test drive and then I was sold from that. It’s the 4.2 v8, only round out yesterday that they do a v12!

 

 

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