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      10-13-2010, 07:54 AM   #1
jannisa
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DCT fluid change

After a long debate on whether or not to change the "longlife" fluid in the transmission the conclusion was that it is not necessary and in fact it can lead to fealure. If you are on the conservative side (I am) wait at least until you have passed 80.000km and change both fluid (Pentosin FFL4 - BMW DCTF-1) and the "pan" of the carter of the transmission where the filter is located. Yes, both are expensive. In case you try to change the fluid only you probably won't be able to get more than 5lt of the total 9,5lt capacity of the transmission out as there are several components which don't give access like the dct-oil cooler for example. Plus there is always the danger of air leaking into the system and then it's adios'. Official dealers under BMWNA refuse to undertake this operation even upon customers request.
For those interested find attached a bulletin for the M3 transmission


SI B28 03 08
Double-Clutch Transmission with Drivelogic July 2008
Technical Service

SUBJECT
M Double-Clutch Transmission with Drivelogic - Transmission Filling and Fluid Level Checking Procedure
MODEL
E90, E92, E93 M3 with S65 and M DCT transmission
SITUATION
The current version of BMW TIS does not contain the M DCT (GS7D36SG) transmission fluid filling (fluid checking) procedure. Use the following procedure when the M DCT fluid fill (check) is required.
Important:
The M Double-Clutch Transmission (DCT) requires a special lubricant/hydraulic fluid: DCTF-1 Pentosin (P/N 83 22 2 147 477). This fluid is specific to the double-clutch transmission and should not be substituted with any other product.
Substituting the DCTF-1 Pentosin in M Double-Clutch Transmission (GS7D36SG) may cause significant damage to the internal clutches of the transmission assembly, requiring replacement of the complete gearbox, transmission oil cooler, and cooler lines.
The BMW DCTF-1 Pentosin fluid does not require regular service. It is an extended-life type of fluid and should not be replaced. Currently the fluid is in extremely short supply, and can be obtained only after a PuMA case is submitted to TeileClearing (Enhanced Technical Support). Refer to SI B28 02 08 (May 2008) for more information related to M DCT TeileClearing.
1. The vehicle needs to be leveled and secured on the appropriate workshop lift. Connect the vehicle to the DIS/GT1 loaded with the current version of diagnostic software (V53 or higher).

2. Remove the transmission's under-cover to gain access to the refilling plug (1). Make sure that the transmission is at ambient temperature (engine should not be warmed up).
3. Using an Allen M8 wrench, loosen the fluid filling plug (1).
4. For refilling (empty gearbox after repair):
• Remove the filling plug from the transmission housing and refill the transmission with approximately 8 liters of DCTF-1 fluid, until it starts to overflow.
5. For checking the fluid level:
Carefully start removing the filler plug until the DCTF-1 fluid starts to flow.
Do not remove the filler plug completely!!!
With the correct fluid level and the gearbox filler plug removed while the engine is NOT running, approximately 1.5 liters of transmission fluid will escape, leaving the gearbox underfilled. (The total capacity of the DCT transmission with oil cooler and cooler lines is approximately 9.5 liters.)

6. Install the filler plug (do not torque it yet).
7. From the DIS/GT1 diagnosis menu, select
Service Functions, Transmission Controls, Calibrations, and Oil calibration.
8. Start the engine with the DCT gearbox in the P position.
9. Follow the "Oil calibration" test plan by running the engine at 2,000 rpm for 1 minute (reaching the maximum cooler line pressure of 5 bars).
10. Using DIS/GT1, observe the transmission fluid temperature. When it reaches approximately 40° C, open the filler plug again (with the engine running), and top off the fluid level until it starts to overflow.
11. Install the filler plug and torque it to 25 +/- 3 Nm.
WARRANTY INFORMATION
For information only
[ Copyright © 2008 BMW of North America, LLC ]
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      01-26-2015, 06:05 AM   #2
HowieZ4
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Hi folks, Even though this is an old post, it has helped tremendously with my DCT fluid kerfuffle by my indy workshop last week.

My transmission oil pan had a bit of a leak/weep common to our DCT so I decided to change the pan and replace the trans oil. The trouble that followed could have been a costly one had it not been caught early.

Draining the oil and replacing the pan was simple enough but refilling the transmission oil proved to be a bit more tricky. Because there's no electronic oil level sensor or dipstick, it was pretty much a guess work filling the oil until it was overflowing.

Well, it started overflowing at 6.5 liters and the mechanic felt it was full and stopped there. He didn't follow the multiple procedure as the above OP post nor did he use the DIS to perform the oil calibration steps.

Driving home that day was fine, shifts felt smoother and the judder from 1st gear was gone. Great, I'm thinking. The next morning, I started the car and pulled out but the transmission felt like it was slipping. Half a block down the road, the car stalled and the DCT shifted into Neutral by itself. We managed to limp back home and then the car stalled again and this time it wouldn't start.

Reading the OP post, it indicated that the DCT capacity is 9.5 liters so 6.5 liters refilled the day before seemed a bit off. This insufficient oil could have damaged my transmission in a costly way. The workshop filled another 1.5 liters and all seemed ok.

The next day, car drove normally but had a bit of rough gear shift. It then got worse and the car stalled but did start again so managed to get it to another Bmw specialist workshop.

This time, the oil level was checked and the refill procedure was followed using the DIS oil calibration steps and DCT is working fine again.

Moral of the story is that when Bmw says the transmission/DCT oil is lifetime, they mean don't touch it!

My car has about 35k KM and the original factory oil was clear and the filter was clean when it was removed. Unless you have a bad leak from the pan, do not change the "lifetime" transmission oil. And if you have to, take it to a reliable Bmw dealer or a competent workshop to get it done.

Cheers, Howie
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      01-26-2015, 08:32 AM   #3
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I agree - taking this particular service to a dealer is recommended. But I can't understand why replacing the oil is so fraught with danger. The damn thing was filled at the factory in the first place and the service bulletin details proper replacement procedure. No oil lasts forever. BMW's "lifetime" fills means when your component fails, "lifetime" is up.
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      01-26-2015, 09:14 AM   #4
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The fraught with danger is that it is very easy to under or over fill the transmission oil since there's no gauge or dipstick.

If there is insufficient oil in the transmission, the components will wear faster, or worse, fail.

Too much oil and the transmission "drowns" and gets air logged, which affects the flow of the oil and causes overheating.

The oil overflow technique is also not a very reliable way to ascertain the correct amount in the transmission components as there's oil hiding in the oil cooler and hoses.

Also, to get sufficient oil to reach all the transmission components, the engine has to run, gearbox engaged, and the oil has to reach 40 degrees and pressure has to get to 5 bars, all while pumping oil from under the car on the side of the transmission wall while excess burning oil is overflowing out at the same time. I could see the guys working on the car flinching as the oil burned them.

Bmw dealers have ATF machines that automate all this but indy workshops usually do not.

Cheers. Howie
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      01-26-2015, 09:36 AM   #5
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Glad this thread became useful after 4+ years and thanks for your actual remarks, it will make a great future reference. Moral of the story don't flush it before you have reached 80-100k km.
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      01-26-2015, 09:51 AM   #6
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Good to see you here Jannisa. I really owe you a big thanks for posting this DCT fluid info as it literally saved my transmission.

I would not have known my trans oil was under filled nor insisted on the DIS calibration had it not been for your post.

No more trans oil change for me until I hit 100K km.

Thanks again! Howie
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      01-27-2015, 02:21 AM   #7
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Thanks for your kind words, Howie. I 'm really glad that some facts that didn't cost me anything at all were able to save you from a big bill out of nowhere.
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      01-27-2015, 09:53 AM   #8
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Janissa, it would have been a big bill indeed if either the transmission or the Dct got damaged from insufficient oil.

It took time, effort, and consideration to make your post and that speaks very highly of you. Many thanks again for your help. Kind regards, Howie
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      01-27-2015, 10:31 AM   #9
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Beautiful indeed
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      01-27-2015, 12:16 PM   #10
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Quote:
Originally Posted by HowieZ4 View Post
...it is very easy to under or over fill the transmission oil since there's no gauge or dipstick....
I was under the impression that you cannot over fill the transmission. The reason being is that once the vehicle gets above 40c the fluid expands and would overflow just when the engine is off and cold. We all know that when the engine is off that there are parts within the tranny that hold up to 2 liters of fluid which drains back into the reservoir. So by running the engine at 1K RPM until the fluid gets to 40C allows those parts to consume (I mean fill with) fluid thus creating the 2 liter void which can then be added using the fill hole. If what I have been told is incorrect someone needs to let me know.
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      01-27-2015, 07:26 PM   #11
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The procedure you describe is correct. Unfortunately, the workshop didn't follow this procedure the first time so there was no 2 liter void before the fill hole overflowed so the transmission was under filled. That caused all sorts of issues with the trans and DCT.

Subsequently, topping up the second time, they used a hand held pump and put in too much. So yes, they can overfill the trans oil if they don't follow the DIS oil calibration procedure.

Cheers, Howie
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      01-28-2015, 01:59 PM   #12
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I heavily complained about NO dip stick.
I have serviced the trans. fluid change, pan gaskets etc. on all of my cars and boats for as long as I can remember.
I hate too on this DCT that there is no self serviceable parts. However understanding that in this (from my understanding a $8-10K???? transmission), when looking at where it came from- Direct from BMW racing, The M3 and more, I will relinquish my Z to BMW for this very expensive fluid change when needed. There is no saving any $$ if this job is done wrong.
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      01-29-2015, 03:02 AM   #13
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In hindsight, I should have taken the car to a Bmw dealer to change the transmission oil.

I didn't realize it was such a delicate job. Just glad the transmission/gearbox didn't blow up! Cheers. Howie
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      01-29-2015, 11:52 AM   #14
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Quote:
Originally Posted by HowieZ4 View Post
In hindsight, I should have taken the car to a Bmw dealer to change the transmission oil.

I didn't realize it was such a delicate job. Just glad the transmission/gearbox didn't blow up! Cheers. Howie
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