Well I knew it was too good to be true, wafting along in our Rangey for the last three months since we got it thinking that the gearbox feels fine...

Today it let the better half down, showing transfail and wouldn't drive. Managed to get it into a lay-by by turning off and on again and it drove a short distance and then towed it to a local indie. They've found black oil and shiny bits in the gear oil so looks like the gearbox has given up on us.

Knew it was a weak point I suppose, so inevitable eventually.

However I'm in Barnoldswick, Lancashire. Could anyone advise on where to get a replacement box or have one fitted locally. They are listed on eBay, but are they reputable companies or will I be buying more trouble?

I have two options, get a box and get my indie to fit for me, or take to someone who can take out and recon box as one job. Latter may be best option in case anything goes wrong with it after fitting, but only if there is somewhere local(ish) to me, ie East Lancashire, Blackburn, Preston or Further east towards Keighley, Bradford. If it's too far it'll cost a fortune to have it transported.

Any recommendations welcome.

Also would rather do this once, so happy to pay a bit more if I can be sure it will have the upgraded valves etc. Do we know who does this, or is it standard practice when refurbishing these box's?

Thanks

John

Judging by all of the �just out of warranty� (or, in some fortunate cases, still just within warranty) failures reported on the forums for re-manufactured 5L40-E transmissions for TD6 L322s I would say that, as a rule, the source of the original problem (i.e. wear in the valve bodies/pump housing) had not been addressed when the transmission was reconditioned � mainly due to cost. You either need to get specific assurance that the valve body assembly/pump housing has been tested and replaced (or at least fitted with Sonnax valves), or maybe source the valve body assembly yourself.

If you look at the website for STA at Aylesbury, just as an example, (www.staautogearbox.co.uk) you will see that they have a Hydra-Test machine to check the valve bodies and they fit Sonnax valves where necessary. I use a company on the Wirral to test my rebuilt valve body assemblies (www.valvebodyuk.co.uk) and they also supply tested and �Sonnaxed� GM 5L40-E units. Hopefully other forum members will chip in with any companies they can recommend.

Phil

Phil, a question. In view of the fact that wear in the valve bodies seems to be one of the primary causes of failure in the GM box, would it be a consideration to change the valve body for a Sonnax one whilst the box is still performing? Provided that there is no apparent "glitter" in the oil. John
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Cheers Phil, I'll give the company on the Wirral a call tomorrow to see if they have an exchange unit.

Weegie wrote:

Phil, a question. In view of the fact that wear in the valve bodies seems to be one of the primary causes of failure in the GM box, would it be a consideration to change the valve body for a Sonnax one whilst the box is still performing? Provided that there is no apparent "glitter" in the oil.

Yes, in principle, I think this would be a sensible approach provided the transmission�s clutch packs were still in serviceable condition. Clearly this is hard to judge without stripping the transmission � all we know is once there�s metallic debris in the fluid/sump it�s too late.

Sonnax produce kits for no less than ten different valve locations for the 5L40-E

Rear valve body :
1. Low pressure control valve
2. Reverse lockout valve
3. 4-5 shift control valve
Front valve body :
4. Feed limit valve
5. TCC regulator apply valve
6. 3-4 shift control valve
7. Safety mode valve
Pump cover :
8. TCC control & enable valves
9. Line boost valve
10. Pressure regulator valve

so I think it would be necessary to test the bodies on a Hydra-Test machine, or similar, to determine exactly which of the valves requires replacement. Each valve kit costs between �50 and �100 so, together with the labour charge for reaming the bores, this would soon prove uneconomic if more valves are replaced than necessary.

Click image to enlarge

It�s also important to remember that several valves are in the pump cover rather than the valve body assembly so this would also have to be tested.

Phil

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Gritstoner wrote:

Cheers Phil, I'll give the company on the Wirral a call tomorrow to see if they have an exchange unit.

Thanks for that Phil. Having replaced the filter a couple of times it seemed straightforward to replace the valve block with one already "Sonnaxed". Apparently there is probably more to it than that.

Cost would also be a consideration. Perhaps a bit oversimplifying but it occurred to me that changing the block would do no harm but i suppose any debris which might exist would damage the Sonnax valves too.

PS.Sorry for the hijack, Gritstoner. John
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John,

I�m concerned that I came across as sounding negative about your suggestion, and I really hadn�t meant to be. Provided the valve bodies/pump housing are tested so that only the necessary valves are replaced then it could be a very cost-effective way of avoiding a much larger bill in the future together with all the inconvenience of a trashed transmission. To give some idea of cost, a guy on another L322 forum was recently quoted �255 for an overhauled 5L40-E valve body assembly, with the necessary Sonnax modifications, by Valve Bodies UK.

Phil

Phil, I didn't take it as negative at all. Constructive rather than negative.

The cost of the valve body assembly doesn't seem excessive in itself. Especially as it could save a lot of grief later.

I am unclear what would be involved in testing the valve bodies/pump assembly and how much is involved in stripping out etc.

As I understand it the valve body assembly is a question of dropping it out of the gearbox which seems straightforward (I might be up a gum tree with that! ) but, excuse me being obtuse, what is involved with the pump housing?

Regards John
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2005 TD6 Java Black Vogue - Written off!!
GAP iiD BT-Sold

"what is involved with the pump housing?"
The gearbox has to be removed from the vehicle, then the torque converter removed. The pump housing is behind the torque converter.
The oil pump in the pump housing is driven by a drive dog on the end of the torque converter. As I understand there is a couple of piston chambers and a relief valve in the pump housing.

Steve. 1968 Series IIA Pastel Green, nearly there project

Thanks, Steve. I had a look at Rave but wasn't quite sure.  John
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Yes, the pump housing is bolted to the back of the bellhousing

Click image to enlarge

Click image to enlarge

Click image to enlarge

Click image to enlarge

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Thanks, Phil.  John
2008 Stornoway Grey 3.6 Tdv8 Vogue - SOLD
2005 TD6 Java Black Vogue - Written off!!
GAP iiD BT-Sold

John - no hijack, this is all interesting and useful stuff.

Checked into my warranty and I'm not going to have as much control over the repair as I would like. Its in a garage and it looks like it will be sent for repair or an exchange unit fitted, we'll see... should know more towards the end of this next week.

As it is I didn't call the garages Phil recommended as it's up to the garage to sort. I'm not used to not having control, but then I'm not used to having a warranty! Hopefully I'll get a good job that lasts, but if it goes again I'll sort it myself with guidance from members on here such as Phil!

Thanks all, I'll update as things progress.

Thanks for this post. I have just purchased and as Swambo says i did my dues diligence and now after a purchase finding out more.
Why oh why cant someone invent an automatic that is not complcated and doesnt pack up in 100,000 kms.
I will be getting my gearbox flushed this week and its also buttery smooth with changes so what got me going here was that Gritstoner's box went.
I surmise that these things can go even the fluid is all nice and clean.
And once you get the sonnax parts in, how much life will the box have?