Bemble said:
If you message me with your email address I can send you the official repair manual. The cheapest method of dealing with the piston seals is probably to use the Seal-e-Zee cones and freezing spray.



https://www.hydratest.co.uk/transmission-tools

Phil
Click to expand...

Ok Phil you got me I will simply have to rebuild it now lol I would very much appreciated if you can send me that my manual I will pm you my email address right away. Also the added benefit of rebuilding the gearbox myself means I won't live in fear of it blowing up again because I will know that I can just rebuild it myself. Are The Sonnax valves Used with the original valve body? Do you have a rough idea of the cost involved for parts when rebuilding one of these units? yes iv'e seen those cone things before have you tried this method yourself?
 
Well that didn’t take a lot of persuading! Hopefully you will have received the repair manual(s) by now. 100% agree regarding the feeling you’ll have after fixing your own transmission – you’ll never worry about it again.

Sonnax produce a large selection of replacement valves for the 5L40-E valve bodies and oil pump cover. Unless you have the necessary kit for vacuum testing the valves

5L40EVacuumTest.jpg


you will need to send the valve body assembly away for testing (e.g. www.valvebodyuk.co.uk, but I’m sure there are others) and they will replace just the valves that it needs. Otherwise it would be prohibitively expensive to just replace the lot.

GM_5L40-E_VBL_zpsrehcarwj.jpg


RearControlValveBody-1.jpg


FrontControlValveBody-1.jpg


OilPumpCover.jpg


The rebuild will cost you ‘several hundred’ pounds in parts for sure, but I suspect it will be cheaper than a manual gearbox conversion, and certainly cheaper than getting yet another poorly re-manufactured transmission from some dodgy rebuilder.

I’ve personally never put together a 5L40-E (I specialise in the ZF transmissions) so I’m afraid I have no experience of using the cones and the freezing spray (the ZF transmissions just use plain O-rings for the clutch piston seals). I’m sure it would be very helpful to people on here if you could produce a write-up with photographs showing the complete process, if you go ahead.

Phil
 
Phil you are truly a legend!
yes you persuaded me! the manual conversion was A very tempting option for me and I love the simplicity of a manual but the luxury and comfort that the automatic offers is far superior and with the knowledge you have now passed on to me through the official rebuild manuals makes this doable project for myself. I received all the manuals as promised and yes I agree with you I will document this experience I am thinking about doing a video series and uploading it to YouTube this will hopefully give others who are in the same predicament the confidence to go ahead and rebuild their transmissions themselves these cars are not very valuable anymore, and most people who own them are not very well off, for a lot of people a bad transmission means the end of the road for their precious old Range Rove so it would be nice to help out a few people.
 
directclutchinputhub2.jpg
directclutchinputhub2.jpg

Also any idea where I could get my hands on one of these? would a good used part be sufficient or would it have to be new do you think?
 
^^^^
I linked to Jpat earlier. Had several bits off them for my ZF earlier this year. Found them easy to deal with, sensible prices & quick delivery.Take cards over the phone.
Part number in the list is the one in the parts pic with numbers inf front. In this case 144 is in front of most then the 3 digit off the pic.
Given the reputation of that bit for unravelling - who thought making a tube that way was a good idea FFS - I'd be looking for new!
 
Ratae said:
^^^^
I linked to Jpat earlier. Had several bits off them for my ZF earlier this year. Found them easy to deal with, sensible prices & quick delivery.Take cards over the phone.
Part number in the list is the one in the parts pic with numbers inf front. In this case 144 is in front of most then the 3 digit off the pic.
Given the reputation of that bit for unravelling - who thought making a tube that way was a good idea FFS - I'd be looking for new!
Click to expand...
Thanks for the link but that company doesn't actually stock any hardware parts, i've only been able to find used parts so far.
 
I finally got a scan tool on it today it came up as P0894 transmission component slipping! does that sound like a broken direct clutch?
 
bhTD6 said:
Thanks for the link but that company doesn't actually stock any hardware parts, i've only been able to find used parts so far.
Click to expand...
Are you looking at the correct page? http://jpat.co.uk/automatic-transmission-parts.html

States quite clearly :
As stockists of the widest range of automatic transmission parts in the UK, our aim is to provide you with the parts you need, via next day deliver, if you are based within the UK (European and international delivery is also available - times vary according to country). At the last count, we held over 32,000 different lines in stock
 
OP has said they don't stock the parts. I'm presuming he has phoned & spoken to them - although he hasn't responded to that question from others.
I had gaskets & seals - incl the teflon replacements for the metal input shaft seals from them for my ZF which were megabucks if ordered form USA but a couple of quid from them - so can't answer what major items they may or may not stock.
Got to be worth a phone call though.
 
Ratae said:
OP has said they don't stock the parts. I'm presuming he has phoned & spoken to them - although he hasn't responded to that question from others.
I had gaskets & seals - incl the teflon replacements for the metal input shaft seals from them for my ZF which were megabucks if ordered form USA but a couple of quid from them - so can't answer what major items they may or may not stock.
Got to be worth a phone call though.
Click to expand...

They do. I'm guessing he hasnt actually spoken to them.
 
Ratae said:
OP has said they don't stock the parts. I'm presuming he has phoned & spoken to them - although he hasn't responded to that question from others.
I had gaskets & seals - incl the teflon replacements for the metal input shaft seals from them for my ZF which were megabucks if ordered form USA but a couple of quid from them - so can't answer what major items they may or may not stock.
Got to be worth a phone call though.
Click to expand...
tanis8472 said:
They do. I'm guessing he hasnt actually spoken to them.
Click to expand...

Just to be pedantic he stated "that company doesn't actually stock any hardware parts". Which like yourself, Tanis and HC, would lead me to believe he hasn't phoned them, didnt click his engine model and made an incorrect assumption.
However, until he comes back and answers previous questions we're all left wondering ;)
 
I have an account with JPAT and I’m ordering some (ZF) parts from them tomorrow so I’ll ask them to quote for a 5L40-E direct clutch hub/shaft at the same time.

Phil
 
From JPAT:

Shaft, Direct clutch hub and shaft 191mm long, JPAT p/n N224 29 04 = £93.75 +VAT

Phil

P.S. We should just keep in mind that we don't know for certain that this component has failed and caused the issue with 4th & 5th gears so I certainly wouldn't recommend shelling out for one until the transmission is apart and the failure confirmed (obviously)
 
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