High Mileage ZF5HP24 transmission oil change (not a DIY)

Lungs033

Member
I recently did an auto transmission oil change on a ZF5HP24. Having read on these boxes failing at high mileage if there has been no prior regular maintenance I decided to still go ahead with it.

The vehicle is a 2002 e39 540i with 258 000 km on the clock. The issue I had when I got the car was the "pulsing/fluctuating" rpm with very slight torque converter rattle on 4th or 5th gear at cruising speeds (I am somewhat a granny driver). The vehicle drove and shifted perfectly fine with this issue. The rpm is fluctuating is even more aggressive on cruise control.

The transmission then developed a hard shift from 2nd to 1st when stopping somewhat quickly. The pulsing then started occurring more frequently and the rattle got slightly louder. To me this said torque converter is on its way out or the trans is not getting the required "hydraulic pressure". I then took the gamble to change the oil as a measure to prolong the torque converter replacement.

I purchased the oil (ravenol 5/4hp), filter and gasket (Febi).
20250427_101448.jpg
I started the job and just after cracking the sump bolt I had to attend to something else, leaving the oil draining overnight (6is liters). What came out was black oil which didn't stink at all as other forums state. (A glimmer of hope as I thought the oil/filter had been done before).
20250427_125723.jpg
Filter removed was a Filtran dated 20 Feb 2002. the fear of not having a driving car at this point was at peak.
20250427_094838.jpg 20250427_092338.jpg
The new filter came with a gasket, filter screws and two O rings, one already installed on the filter.
20250427_102001.jpg
The new oil was surprisingly very light in colour and had somewhat of a strong smell but nothing unbearable.
20250427_102450.jpg
I did the whole refill and 30 to 50 degree fill (6ish liters), working in this area is not fun because the car gets to temp quite easily and the exhaust is next to the fill plug. After finishing, I took the vehicle for a test drive. The vehicle can now maintain a higher gear lowe speed without down shifting or feeling out of place. The trans doesn't have the hard shift from 2nd to 1st. The rattle is gone but the pulsing/fluctuating rpm is still present but a bit more gentle even on cruise control.

The main question I have on my mind now is how much more KM's I'll get after this before a rebuild or a second hand box?, has anyone done this aswell on their vehicle and what was your experience?.
 

FISAACS

Member
I recently did an auto transmission oil change on a ZF5HP24. Having read on these boxes failing at high mileage if there has been no prior regular maintenance I decided to still go ahead with it.

The vehicle is a 2002 e39 540i with 258 000 km on the clock. The issue I had when I got the car was the "pulsing/fluctuating" rpm with very slight torque converter rattle on 4th or 5th gear at cruising speeds (I am somewhat a granny driver). The vehicle drove and shifted perfectly fine with this issue. The rpm is fluctuating is even more aggressive on cruise control.

The transmission then developed a hard shift from 2nd to 1st when stopping somewhat quickly. The pulsing then started occurring more frequently and the rattle got slightly louder. To me this said torque converter is on its way out or the trans is not getting the required "hydraulic pressure". I then took the gamble to change the oil as a measure to prolong the torque converter replacement.

I purchased the oil (ravenol 5/4hp), filter and gasket (Febi).
View attachment 28053
I started the job and just after cracking the sump bolt I had to attend to something else, leaving the oil draining overnight (6is liters). What came out was black oil which didn't stink at all as other forums state. (A glimmer of hope as I thought the oil/filter had been done before).
View attachment 28055
Filter removed was a Filtran dated 20 Feb 2002. the fear of not having a driving car at this point was at peak.
View attachment 28054 View attachment 28058
The new filter came with a gasket, filter screws and two O rings, one already installed on the filter.
View attachment 28068
The new oil was surprisingly very light in colour and had somewhat of a strong smell but nothing unbearable.
View attachment 28059
I did the whole refill and 30 to 50 degree fill (6ish liters), working in this area is not fun because the car gets to temp quite easily and the exhaust is next to the fill plug. After finishing, I took the vehicle for a test drive. The vehicle can now maintain a higher gear lowe speed without down shifting or feeling out of place. The trans doesn't have the hard shift from 2nd to 1st. The rattle is gone but the pulsing/fluctuating rpm is still present but a bit more gentle even on cruise control.

The main question I have on my mind now is how much more KM's I'll get after this before a rebuild or a second hand box?, has anyone done this aswell on their vehicle and what was your experience?.
Good work bro. I had my 5hp24's torque converter and valve body rebuilt by All-O-Matic. They're based in Selby , Jhb. Could be worth your while to get yours diagnosed by them.

My car's about a month or so from being complete and only then will I be able to give feedback on the transmission performance.
 

Peter@AEW

BMWFanatics Advertiser
Official Advertiser
ZF will tell you that at 250K kms the oil should not be changed as the clutch particles circulating will aid in positive gear engagement.

By all accounts you are likely to have gear issues shortly.

I have steered away from doing oil changes on high milers and had my gearbox rebuilt at 200K kms.
Sincerely wish you good luck
 

Lungs033

Member
Good work bro. I had my 5hp24's torque converter and valve body rebuilt by All-O-Matic. They're based in Selby , Jhb. Could be worth your while to get yours diagnosed by them.

My car's about a month or so from being complete and only then will I be able to give feedback on the transmission performance.
Ill definitely start saving up for a complete rebuild
 

Lungs033

Member
ZF will tell you that at 250K kms the oil should not be changed as the clutch particles circulating will aid in positive gear engagement.

By all accounts you are likely to have gear issues shortly.

I have steered away from doing oil changes on high milers and had my gearbox rebuilt at 200K kms.
Sincerely wish you good luck
How soon will the issues come and is this inevitable even if adaptations were not reset?. I'll be happy if I get 5 000Km at least before complete failure.
 

Peter@AEW

BMWFanatics Advertiser
Official Advertiser
How soon will the issues come and is this inevitable even if adaptations were not reset?. I'll be happy if I get 5 000Km at least before complete failure.
Not possible to predict unfortunately.
You might get lucky and do well beyond the 5K
 

MLorgat

Member
Would it not be cheaper to get a used box? one that has relatively low mileage

ZF offer the service where they run diagnostics and check out the box alone, but they charge 1k something last I checked
 

Lungs033

Member
Can a diagnostic test be run on a free standing gearbox not mounted to the vehicle?.

A used box is definitely another option if one can have it tested otherwise most of the time one will be buying it blind sighted with no history on the box unless if it comes with a decent guarantee.

Another option could be a DIY rebuild which will save a few pennies on the labour but will need time and patience to get it done right.
 

MLorgat

Member
As far as I remember, they can check out a free standing gearbox. Not sure how they do it, whether they hook it up on a test bench or do physical checks etc

I see Mat Armstrong rebuilt a Ferrari gearbox DIY style, if you're handy like that, it's definitely worth trying especially if you can get the parts at a decent price.
 

FISAACS

Member
Can a diagnostic test be run on a free standing gearbox not mounted to the vehicle?.

A used box is definitely another option if one can have it tested otherwise most of the time one will be buying it blind sighted with no history on the box unless if it comes with a decent guarantee.

Another option could be a DIY rebuild which will save a few pennies on the labour but will need time and patience to get it done right.
All-O-Matic won't sell you the components needed to refresh the valve body and torque converter but they will do the rebuild themselves. They will sell you the clutch kit though, if available.

Doing it yourself will likely cost about +-R20k in parts, excluding the gearbox oil,but getting it wrong might be costly.

Reach out to the place refered by Peter as well as All-O-Matic for full rebuild pricing, timelines as well as warranty period.

Doing it yourself will save you at most about R20k less whatever you value your time at.

Good luck bro
 

Mytfine

Well-known member
Yeah, how long is a piece of string, mines was on 300k when the oil cooler gave in and I did a change of oil, was absolutely perfect before that. Did less than 2000km before wierd little things started happening, like flutter and a little slip now and then , flogged it before it got worse, and yes I did mention to the new owner the car would need a gbox in the near future but he had a workshop so didn't concern him.
 
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