All i can add from my experience, on replacing just the o ring, (see earlier pages/posts) was that, after refitting box, I had a 1st to 2nd issue, when i thought the fluid was full and it had sort of then gobbled it up and was then low.
On first test drive, would not hardly move, (jerking) but all on very low revs etc.(so not to damage etc) , then refilled and was still slightly low, and i had a bad squeal sound and 'snatching' of the 2nd gear from 1st. it drove ok through gears. but when turning it was 'no drive' symptom, (bong! transfailsafe error etc) and straighten up, and 'box would squeel and snatch into gear. I got the car onto level ground position, with enough access under, and removed front fill plug, warmed up 20 mins, filled, re-primed through the gears, refilled, left it running, each time allowing time for fluid to be sucked up, and then a final fill till overflowing. -allow to thin out to a tiny dribble, and replace. test drove and it was fine after that.
You have certainly been through a long battle with this issue, and just wonder if you have a low filled gearbox at the end of all other work etc.

sorry for the delay, but these days are full of problems .. even the automatic transmission of my Skoda 4x4 stuck in 1st after 120000km.and need replace gearbox..
anyway thanks for the advice, but I removed transmision three times in two weeks and every time I took the same amount of oil. I filled i as you say, in the standard manual rave way, with an electric pump of 12v. I'm sure the level is right ... checked many times . may be wrong once but not three time hope.
I had already replaced the oil a year ago and had no problems.
now we have to wait the arrival of sparag spare and see
I think we will know until this week . I replaced many parts..

wandering the web I noticed ebay item eBay Item No. 321835906452 for RECONDITIONED ZF5HP24 from a UK seller, but invoice show repair service for a GM 5140e, ie diesel X5.. so not only Italians ...are foxes

today gearbox refitted with same problem, (between 1st and 2nd , lost drive for a second and bang..) so at this point I give up, because became very hard. If anyone have an idea I here ..
Just a fast question: Zf manual says as image below.

Andrew, your story is very dissapointing. a sad ending..

regarding that repaired x5 gearbox. well spotted that it was a gm gearbox on the invoice, however, if you look a little deeper, and use our DVLA (govenment website for cars etc) you can enter that reg, and it is known to be a PETROL 4.4 and now declared off road, possibly as its being broken up etc. so, the gearbox invoice, is wrong, on the line GMxxxx etc. it might be worth ringing them, to hear their comments etc. also, you could send the owner a kind letter, asking him what the story is on the cars' gearbox and end of the car etc. his address is on the left. ask him to email you etc.

use this dvla website, enter reg from invoice. and just the make 'bmw' https://www.vehicleenquiry.service.gov.uk/
also, its possible here to find a takeout gearbox ( from wrecked car) for around £500 if you wait etc. getting it to italy, is next issue. i have heard of some sellers, not posting to italy. seems there are difficulties. etc.

edit. on this thread, http://www.fullfatrr.com/forum/topic33795.html RRphil has mentioned this firm in that post, so they must be good. (mackies)

Yes John, really sad ending ..about transmission thanks for check and interest, but is a little expensive for my opinion, anyway good.
I think continue with my gearbox, because many parts are new and I believe the problem is the valve body, so I want find somebody that can test it.
one hour ago I was check solenoid valve a

andrew.aa wrote:

today gearbox refitted with same problem, (between 1st and 2nd , lost drive for a second and bang..) so at this point I give up, because became very hard. If anyone have an idea I here ..
Just a fast question: Zf manual says as image below.

I belive as collar meand the red arrow side and not the green arrow ..right?

The outer race of the one-way (sprag) clutch should rotate clockwise (but not anticlockwise) when the F-clutch drum is held stationary.

Click image to enlarge

Phil

Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated

Thanks Phil, but I'm not sure what mean with ''the collar at the top'' .
When I put the inner sprag race, I done as follow image from manual, and checked without F drum

Phil, why in R position lever, MV1 is ON and MV2 is OFF?

andrew.aa wrote:

I'm not sure what mean with ''the collar at the top''

Quote:

Internal sprag rotate free on Both directions.. but I don't know how is possible and where wrong as internal freewheel is new can I check without remove transmission?

andrew.aa wrote:

Phil, why in R position lever, MV1 is ON and MV2 is OFF?

andrew.aa wrote:

wandering the web I noticed ebay item eBay Item No. 321835906452 for RECONDITIONED ZF5HP24 from a UK seller

Sorry to be banging on about this yet again but it’s so common to see - just like in this eBay listing - a 5HP24 transmission being sold as suitable for both the Range Rover and the BMW X5. This is incorrect. The E53 and L322 have different transfer boxes so the output shaft and mounting flange are different on the two transmissions. The L322 uses a ‘long’ output shaft and the E53 uses a ‘standard’ output shaft (as used in RWD BMW and Jaguar models) but with a separate extension shaft.

Click image to enlarge

Click image to enlarge

Only the ‘032’ model (i.e. model number 1058 000 032) of the 5HP24 will fit the L322. A ‘029’ or ‘034’ model from a 4.4i or 4.6is BMW X5 will not fit the L322.

My apologies for the rant – it just winds me up

Phil

Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated

I want to make the point of the situation.
PHIL

Quote:

Something definitely wrong there. The inner race Should only rotate clockwise and Should solid lock if you try to turn it in the other direction. 1st gear in automatic mode (Drive) will not work if it does not lock. If you engage 1st gear in Manual mode, However, then the F-brake is applied Which will bypass the sprag. In other words, if the engine just revs in Drive When stationary (as if in Neutral) but will set off in Manual 1st gear then there is an issue with the sprag.

my symptoms of low fluid level, were, slight gurgle on first start up. (not sure if it was directly related) refilled again. -then drove off ok, but slipping when trying to go 1- 2 and maybe a bang into gear, or straight to 4th, and transfail bong.! and again slipping gurgling noise. i topped up to what i thought was full, and it was better, drove ok, but it did same 1-2 slipping, when i turned right, this i thought had to be low fluid. -i returned from journey, and raised car into offroad height, (completely level car now....) and slid under to try and refill with syringe method. it took some more.

my interpretation of filling advice, is to keep adding fluid for a period, of say 15 mins, when car nicely warmed up. i cant remember ideal temp, but thouroughly warmed up. keep syringing in fluid untill it dribbles out, catching in tray etc. when this stops, run car for a 10 more mins, to allow it to be fully pumped around. I tried again to get some in. untill it will not fill any more fluid. i then drove it, it was fine, but i then tried and got a small amount more in. to me this was now full. i may have at first 'foamed' the fluid, meaning it was seemingly full, but had bubbles in like beer. telling me wrong level etc. i would confirm the fluid like this before removing. maybe allow to cool, and de-foam, then repeat whole process.

i cant comment on your one way clutch etc. but i belive the low level had something to do with valvebody movements and gurgling.

for it to be full, it should just be dribbling out -then replace cap.

ok, yesterday, I refilled trans with 4,5/lt of atf and the problem is the same. the method was different and I put plastic pipe to the oil radiator on front and filled with 12v electric pump,

after that Started car and checked for correct level from the level plug.
I think remove trans for the last time and send it to a specialist, because I tried every way to solve withous success.