Lmst

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.

Day 17: I may be on vacation, but I still did a little something to make transmission reassembly happen more easily when I get home—my dad helped me make this little "tool" to clamp to the oil pump/A/B/E/C clutch assemblies to get them into proper position, as seen in the YouTube screengrabs. #WeirdCarMastodon #TransmissionRebuild #DIY #ZF #BMW #E39 #WrenchEveryDay

Two small pieces of wood which, when clamped together, form an approximate square with a hole of 22 millimeter diameter in the middle. The two pieces are split across the center of this hole.

A screenshot from a YouTube video showing the large, heavy assembly of clutch packs and transmission oil pump that need to be installed to complete reassembly of the internals of my ZF 5HP19 five-speed automatic transmission.

Screenshot from a YouTube video showing how the two pieces of wood clamp onto the central spline of the clutch pack and oil pump assembly, allowing the clamp to be used as a handle to lower the parts into the transmission case standing on its end.

Day 16: no photos today, but I finished replacing O-rings and friction discs and started reassembly, which is a pain in the rear. Got stuck on trying to get the last few assemblies in (they're supposed to go in as a unit) and ran out of daylight, so I'll have to re-strategize and come back to it. Silver lining: I have zero unaccounted-for parts. #WeirdCarMastodon #TransmissionRebuild #DIY #ZF #BMW #E39 #WrenchEveryDay

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.

Clutch packs and ring gears and oil pumps, oh my! #WeirdCarMastodon #TransmissionRebuild #EngineSwap #ZF #BMW #E39 #DIY #WrenchEveryDay

All of the clutch drums and ring gears and other moving parts have been removed from the ZF 5HP19 five-speed automatic transmission for my 2003 BMW 530i, and are arrayed on a small table covered with a plastic drop cloth. In all, there are 11 assemblies.

Day 14: dismantling the transmission has begun. So far, I've removed the oil pan and the valve body. This is going to be a messy job; I run into more undrained ATF at every turn. I've also already unbolted the transmission oil pump, so unseating and removing that will be job one after lunch. #WeirdCarMastodon #TransmissionRebuild #EngineSwap #BMW #E39 #WrenchEveryDay

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