what the hell!!!

[Martin323i]

OK. I got the new autobox in car. works fine for the most part. now I have a leak somewhere. It's not the seals.

On top of my old box there's a hole (to the back right on top). It seems this is where the atf is coming from on the new box, pissing out at an alarming rate when I go up a hill or when I accelerate the car quickly. Some of the atf lands on the middle exhaust box, burns and the car is engulfed in smoke!

WTF

Should this hole be there? Should it be blocked with something?

[E30BeemerLad]

what model of gearbox is this 4HP 22?

I ask as I could phone my old man and ask him, he's an auto gearbox specialist, but someone will probably answer your query beforehand.

[Martin323i]

Yup 4hp22

[E30BeemerLad]

so just to clarify before I call, the box you have out of the car which is the old one, has a hole at the back top right, but there seems to be no evidence of fluid loss on the old box around this part?

[Martin323i]

Yup

[Martin323i]

the hole is at the back on top in the middle.

Not to the right. I think we've gotten mixed up on the use of the word right here.

[E30BeemerLad]

my old man said the only things he can think of at the tailhousing are a breather pipe which should be there and then the speedo cable entry point. He said there should be some sort of bung around the speedo cable entry point and a blanking plate opposite. Is your speedo still working? If the speedo cable was not pushed in properly then he said the worm would hold it in for a while before it popped out and out comes the fluid.

Any help?

[Martin323i]

Thanks fot your effort and help Beemerlad, really appreciate it.

The speedo still works. But as far as I know the speedo isn't connected to the gearbox on E30's. It's connected to the diff.

I also thought the hole is probably something like an overflow opening or breether. So I guess it should remain open.

But why would the atf come out there. The box definitely isn't overfilled, in fact with the leak, I need to keep topping up to keep the level between the two marks on the dipstick. I check the level with car on level surface, with engine at normal operating temp in park.

[E30BeemerLad]

yeah no probs fella, I can't believe i typed the bit about the speedo cable when I have even fixed my own on the diff I was just saying what the old fella said, "if it has the speedo drive on the box" and didn't think at the time.

I think all you can do is try and do a search for some tech information on the ZF 4HP22, it must be out there somewhere, or even a shitty haines manual or better still Bentley

[Martin323i]

Yeah, I had my new diff installed today and watched them connect the speedo connector.

I have a bentley. Not very good on the auto transmission - no mention of the hole in there. Very thorough on the manual trans though.

Oh well. Car's going to the mechanic again tomorrow so hopefully he can sort it out. But I doubt it. I think I'll have to take it to an auto specialist. Problem is, there are none close by

[E30BeemerLad]

could you take a picture of what you are looking at on the box that is out of the car

email it to reeferb0y@aol.com

I will try to email it to him but he is having computer problems at the moment. He was in the boozer when I just spoke to him and his battery was beeping on his mobile so I am unlikely to have any more news today fella.

Chu has played around with auto boxes I think i'll see if he knows anything

[Martin323i]

Will do mate

The box is at the mechanic's, so I'll only get to it tomorrow morning. Will take pic with cellphone and mail it to you.

Wow, every time I wonder why I keep this car, after it gives me even more crap, I am amazed by the help I get from this forum. It's amazing: I'm in South Africa, in a small town about 400km from Cape Town and I'm getting help from guys and gals in Brittain and around the world. Not to mention that this car has an exhilirating effect on me!

Sorry, just a warm hearted moment there.

[E30BeemerLad]

the offending article

[Martin323i]

Yeah, look down the 'spline' of the box toward the back. Just before it ends and goes down to the output shaft. there's the hole on mine, but on this pic you posted, there seems to be something in there. If I only knew what that is.

[E30BeemerLad]

right, now i know exactly what you mean i will get looking for some technical drawings etc on google, will try the old man first just in case his phone ain't dead

[Martin323i]

right, i'll see if I can find something on realoem.com

[E30BeemerLad]

spoken to my old man and he's none the wiser about the hole with the bung i'm going on about

the part of the box with the bung in it is the tailhouse extension. The governor is housed in there and the old man said if the governor is fcuked then it could have split the casing where it punches a hole in it. Also is the box you have just put in from a crashed car?

all he said you can do is have a look at the other box and maybe swap over the tailhouse extension and see if that cures it, assuming there isn't a hole in the old box.

What was wrong with the old box?

click on this link and then select your gearbox model for an exploded diagram and parts list
http://www.jpat.co.uk/zf.htm

www.jpat.co.uk

[Martin323i]

Nope, no such luck.

[Martin323i]

Nope, no such luck.

[E30BeemerLad]

check my previous post dude

[Martin323i]

Also is the box you have just put in from a crashed car?

What was wrong with the old box?

Probably did come from crashed car. I inspected the box several times before installation. no apparent cracks. The hole in old box is definitely meant to be there. A perfect circle in casing.

The old box turned fluid brown even after several changes and a filter change. A few days ago I started car and a loud scratching came from box or torque converter. Couldn't find someone to work on box so sourced a second hand one with guarantee, so if it's fooked I'll have to take it back.

Oh well, I'll have the mechanic lift it up tomorrow and give it a good inspection. Maybe the housing is cracked.

Will keep you updated.

[E30BeemerLad]

keep with it fella, it'll be worth it.

I nearly binned mine a few months back after finding rot in the bulkhead and the rear bushes gone etc. was gonna break it, but nice to have a project and a bit of rough to throw about.

[Martin323i]

OK. Was just at the mechanics. I opened the old box's extension housing çause I could see something loose in there through the hole.

A strange plastic 'thing' was loose in there. Just when I got it out, the mech came in with the same thing - only not broken - he got from someone somewhere: I didn't ask.

This piece of plastic shit is L-shaped. It's installed inside the extension housing with one 'leg' of the L sticking out the hole. It's an overflow or pressure regulator or something?

The thing is held in place by a circlip on the outside.

I couldn't understand why the old box didn't have this thing and didn't leak. I spoke to one of the other workers there. Apparently another guy who helped to take the box out, for some fcuking reason went and broke off the tip that came out of the box, and decided not to tell anyone! ASSHOLE!

Well, the extension housing will come off today and everything will be put in place and I should have my car - in WORKING order tonight.

Will let you know.

[Geeman]

Glad you managed to get it sorted!

This thread is another testament to the Zone. If we can't help, and someone else can, it's always worth posting up the solution. Nice one guys.

Giles.

[E30BeemerLad]

Good to hear you got it sorted dude

[Martin323i]

Took the car for a drive, everything seems ok.

[oze30]

I seriously hope you didn't have to pay anything for it.. again!

[Martin323i]

I seriously hope you didn't have to pay anything for it.. again!

Nope, the mechanic said it's one of his workers' fault so no charge.