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-   -   Project 5HP19 Transmission: Selector Switch (https://forum.e46fanatics.com/showthread.php?t=931954)

jjrichar 07-08-2012 01:02 AM

Project 5HP19 Transmission: Selector Switch
 
10 Attachment(s)
Selector switch

Link to other parts of the project
https://forum.e46fanatics.com/showthread.php?t=928248

On the side of the transmission is a large switch. This is what tells the car which gear has been selected. You may need to replace this if it fails, or if you are like me, you will want to pull it apart, find out what is wrong with it and fix it.

If it fails, you will get an OBD code saying that the switch is giving an invalid value, and the transmission will go into limp mode (stuck in 4th gear). Unfortunately I know this because my wifeís Audi (which has a 5HP19 transmission) had this issue. Fortunately for BMW owners, the switch is easily accessible from under the car. On the Audi itís a nightmare but thatís another story. I think Iíve mentioned before in other posts that the BMW is far easier to work on than the Audi, and a miles better car. Iíll mention it again. Our problem was fixed by having the engine off, but the ignition turned on, and then running the gear lever back and forth through all the gears over and over about a hundred times. The car hadnít been started for about 6 months (due to us living overseas) and I think some of the contacts maybe got some moisture in them and corroded a little. Who knows? It now works, and I didnít have to pay Audi $800 for a new switch, and about $1500 in labour to fix it. Did I also mention that Audi charge about twice as much for the same parts as BMW?

If you do have a problem with the switch, here are some photos that might help in pulling it apart and fixing it. Disconnect the gear select cable and then remove the switch. Unfortunately the switch is riveted together. Drill the rivet heads off, and then knock them out. To put it back together you can rivet it if you like, or do what I did. Get some small nuts/bolts and with a little loctite have it back like new. Donít worry about the heads of the bolts sticking out, there is plenty of room on each side of the switch for the other components that are around it.


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Arty 07-08-2012 02:58 AM

Cool post, thank you.

Lemonsqr 10-09-2012 05:30 PM

This has no relevance to my manual transmission.....nice writeup none the less

DEADF15H 04-04-2015 07:37 PM

Awesome detailed thread.

jjrichar 11-24-2015 11:51 PM

This might interest some people who have the 5hp19 in their car.

Over the last couple of weeks, when starting the car for the first time in the morning I was getting the transmission cog light on the instrument console. INPA was telling me it was the selector switch.

I changed the selector switch over to the one that I had left over from the project (the one pictured above) and everything worked fine. The only thing that was different was that now the gear lever was slightly stiffer to move. You wouldn't notice the difference unless you had been driving the car every day for a long time.

I then rebuilt the switch that came from the car. When I pulled it apart, it was completely different inside. In an act of buffoonery I didn't take a photo of it, but this switch was simply an arm with four contacts attached, and a corresponding set of contacts they move against. The difference in design is such that the newer type switch (the one that came from my car) turns much more easily than the old style, which was causing the slight increase in stiffness. What I also noticed was that the wiper and contacts were covered in that white paste type grease that you always see on plastic parts. So I cleaned up the contacts and bent the wiper arm contacts slightly so they put a bit more force on the part they slide against. I then riveted it all back together again and installed it in the car.

I'm not 100% sure why, but now the car goes into gear so much better. Previously it would sometimes give a bit of a thunk when selecting D, and generally only on the first time I selected in the morning, and this is with a rebuilt valve body and new fluid throughout. Now it's like butter every time. I can only assume that when you move the gear shift, the TCM senses each of the gear selections and knows what's coming, and with the wipers all cleaned up, it does this better. I'm a bit amazed to be honest and I'm waiting for it to revert to old habits. In the meantime, I can't help but be amazed at the difference each time I select D.

Removing the switch, cleaning it up and putting it back on is about a 1 hr DIY. If I'd known it was going to make such a difference, I would have done it years ago.

speedfreaks 01-21-2016 12:48 AM

really great post, man!
i got this issue a year ago, replace i with the new one and right now it fails again..
idk what's wrong with it, but in a year my car just had about 3000km on clock and this gear selector just act fails again..

DEADF15H 05-30-2016 10:10 AM

Just came back to this thread as I'm replacing mine with a new switch. Not that I don't trust jjrichar's repair, I'm going to pull the old one and replace it, then rebuild it and put it on the shelf. I just didn't want the car to be down very long, as lately I seem to be running into unforeseen issues every time I do a repair or maintenance project.
This is such a well written/elegant DIY. Pictures each step of the way with instructions written onto to the images, so if you need to print it out and take to the car, all the info is right there. I also saved all his images, so if the links get destroyed or lost, just PM me and I'll come back and re-post if jjrichar can't.
I keep a notebook with my Bentley and print out a lot of my DIYs so I can make notes that allow me to shorten the project the next time around. Stuff like, clean contacts and dielectric grease this, or use an articulating nut driver here, stubby ratchet here,or use T27 instead of the T25 as reported in the original DIY. I hate having to get out from under the car over and over.
Well done jjrichar, my guess it took you as long as longer to photograph, write the DIY, edit it, and load the photos than it did to do the job. Your efforts are greatly appreciated.

DEADF15H 06-08-2016 03:54 PM

Be careful with the large nut that holds the linkage to the switch. I stripped the Post :(
Make sure the threads are clean.

spants 02-18-2017 05:22 AM

oh, the insides are different on mine!
 
3 Attachment(s)
Just completed this, thanks to the posters for the how-to.
It was difficult to get under the car due to the low profile of the car (ramps) and the slight slope.

The original pics are slightly misleading as the were not taken of an engine in the car and space is quite tight - particularly if you are lying on the ground.

Anyway, after taking it apart, the insides of mine (UK 2003 330ci Club sport) are different. It is much simpler. A sweeping arm has a row of contacts that touch the tracks. (same as post #5?)
I think only the gold ones are being used. I used contact cleaner and then a bit of silicone (the stuff used in satellite cable installations, not bathrooms!) on them to keep moisture off.

I used a bit of red grease around the seal and the centre part.

I found that 4mm diameter/12mm rivets worked perfectly. Make sure that you rivet from the plastic side so that the rivet expands onto the metal side (see pic)

(In the last pic, there is a rivet missing - this was added before fitting)

DEADF15H 02-18-2017 06:36 AM

Congratulations, thanks for the pictures

Sent from my flame proof Samsung Note 4

CJ74U2NV 05-31-2017 12:05 PM

You have no idea how long I've been searching for something, somewhere, describing this. Thank you!!!

Question though, where the wire harness connects to the car's harness i see a round connector that looks like it simply screws on. Is that how to remove it? Just twist it and pull? Also, which side do you twist? The side towards the front of the car or the rear?

DEADF15H 05-31-2017 01:53 PM

IIRC, you squeeze a lever on the rear plug and turn counter clockwise about a quarter turn and pull it apart, but I'm not sure.
Post a picture, maybe it will get someone else's attention.

Sent from my SAMSUNG-SM-N910A using Tapatalk

CJ74U2NV 05-31-2017 02:00 PM

It's in the first two pictures of the original post..."remove this bolt for plug removal".

jjrichar 06-01-2017 04:13 AM

That bolt is just for the bracket that holds the transmission side of the plug. You only need to remove this if you want to remove the entire harness from the transmission. If not, leave it in place. The car side of the plug simply rotates and pulls off. The car side of the plug had a big lug on it that makes it very simple to rotate and remove.

CJ74U2NV 06-01-2017 07:26 AM

Thanks! That's what I needed to know. I appreciate the reply.

CJ74U2NV 06-18-2017 10:45 AM

Just a quick follow up. I was able to disconnect it, clean it and apply some dilectric grease. Now it works fine.
Thanks again!

John hope 07-16-2017 05:21 AM

Thanks heaps, been scratching my head with th is niggling problem with E46 325i yr2002

99Bandit 08-27-2017 01:51 PM

LOL, our `01 330ci cabby is just going through this. Ordered a new switch from the US, can't get under the car so I'm going to have our BMW guru install it Tuesday, looks like a 5 minute R/R. Going to bookmark this thread and work on the old one when it comes out.

BigCaddy 05-22-2019 01:17 PM

Thanks for the info on the switch. and sorry to resurrect a old post.

I had to drive through some water about six inches deep. sure, I went a bit quick through it but it went fine. I got to my destination about three miles from the water and I wasn't able to get it into reverse. Sometimes it would go in fine but it would be rough as it engages. The transmission was also put into limp mode. I was very concerned about the dreaded no reverse issue with the ZF transmissions. I was thinking that possibly something like a switch got disconnected or wet under the transmission that was causing this. I connected it to the BMW scan tool and cleared all the codes. Once I fired the car back up it ran perfectly. This was a day after going to the water. Is it possible that water got into the switch plug or the switch that could have temporarily caused the short?

02 330ci

jjrichar 05-22-2019 04:56 PM

It may not have gone into the switch, as it's well sealed. It may have gone into the plug. Certainly the symptoms are what you would see if the switch or connectivity to it are failing.


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