Campaign - CVT Transmission Oil Flushing/Replacement
SI M 24 01 02Automatic Transmissions
December 2002
Service Engineering
PERFORM THE PROCEDURE OUTLINED IN THIS SERVICE INFORMATION ON ALL AFFECTED VEHICLES BEFORE CUSTOMER DELIVERY OR THE NEXT TIME THEY ARE IN THE SHOP FOR MAINTENANCE OR REPAIRS.
SUBJECT
Service Action - Flush and Replace CVT Transmission Oil on MINI Cooper
MODEL
MINI Cooper with CVT transmission produced from 08/13/2002 up to 10/23/2002
SITUATION
Incorrect, low viscosity transmission oil was filled into CVT transmissions during production. The use of lower viscosity oil can result in sporadic excessive trans noise accompanied with clutch slippage and reduction of transmitted power. Ultimately, the CVT transmission may fail prematurely.
A service action campaign will be conducted to flush and replace the CVT oil. Customer letters will be mailed out this week notifying them of this Service Action (copy of the letter is included).
While a repair is inconvenient for the customers, it is an opportunity for you to ask them about their MINI motoring experience, answer questions they have about their cars, and show them the latest MINI accessories.
Customers will be impressed when you return their cars cleaned inside and out and with a full tank of gas. Reimbursement information for the fueling costs can be found in the Warranty portion of this bulletin.
AFFECTED VEHICLES
This Service Action involves MINI Cooper vehicles with CVT (Continuously Variable Transmission), which were produced from August 13th, 2002 up to October 23rd, 2002.
In order to determine if a specific vehicle is affected by this Service Action it will be necessary to utilize the "Service Menu" of the DCS (Dealer Communication System). Based on the response of the system, either proceed with the corrective action or take no further action.
The Chassis Number Ranges listed are only for informational purposes and are not to be considered as the only deciding factor.
CORRECTION
The original factory filling of transmission oil must be completely drained and flushed out using the following procedure, to ensure proper function and durability of the transmission.
Esso EZL 799 is the only oil to be used in this transmission.
PROCEDURE
Read through the entire procedure prior to starting the repair. All 21 steps must be carried out as written.
Transmission oil must be drained a total of four times, and filled each time with new original Esso EZL 799 CVT gearbox oil (PN 83 22 081 36 376). For draining and filling-up of CVT transmission refer to RA 00 11 239 (found in BMW TIS).
Drained oil should be disposed of in accordance with local regulations.
Transmission must be shifted through all gears (with engine running) after each time it has been filled-up with fresh oil. This process removes the incorrect oil from all internal components (clutches and valves).
1. Check the Service Action label affixed to the B-pillar:
If the Service action code 6 is punched-out on the label (2), then NO further action is required. If the number differs from 6, or service action label is not found, then continue with step 2.
2. Install vehicle on a lift and remove lower underbody splash shield.
3. Remove both front wheels (refer to RA 36 10 300)
4. Secure the brake disc to the hub by using two short lug bolts M12x1.5x25 (PN 07 11 9 911 694) and flat washers D-25 mm (PN 31 11 1 113 513) in two opposite lug bolt holes. Removing the weight of the wheels reduces the load on the CV joints/axles when vehicle operates on the lift. Torque the short bolts to 100 Nm.
NOTE:
The short bolts and washers (four per work station) used to secure the brake discs can be reused and cannot be claimed for under campaign warranty.
5. Approximately 4.5 liters of oil will be required to fill the transmission during the flushing process.
When using an oil pump as shown, transfer 4.5 liters of oil into a clean container in order to determine the number of full strokes/cycles of the pump lever (depending upon displacement of the hydraulic pump used).
This oil can then be poured back into the storage container.
6. With the transmission oil temperature between 30°C and 50°C, remove CVT drain plug (1).
Care must be taken to prevent scalding
Drain transmission oil. Install and tighten drain plug with its original seal. Since draining procedure is going to be repeated three more times, it is not necessary to apply the final torque at this point.
7. Remove CVT fill/level plug (1)
8. Use special tool PN 90 88 0 248 100 and pump 4.5 liters of EZL 799 oil into the gearbox via the fill/level plug housing.
The special tool can remain connected to the transmission.
9. After filling, shut-off the hose input valve. It is not necessary to remove filling hose.
10. Follow safety precautions specified in RA 00 11 239 while operating transmission on the lift.
^ Engage parking brake, apply foot brake and start engine
^ Run engine for 10 seconds, select trans position "D" and then shift into Steptronic mode
^ With the engine speed increased up to 2500 rpm, shift the transmission into each gear in the following order: 1, 2, 3, 4, 5, and 6.
^ Run for approximately 3 seconds in 6th gear, and then without load (coasting) shift down from 6th to 1st gear.
^ With 1st gear engaged, carefully apply foot brake and once axles have come to a stop, shifi briefly to position "R" (for approximately 2 seconds), and then into position "P".
11. Turn the engine off
12. Drain CVT transmission oil again. Care must be taken to prevent scalding
13. Repeat steps 6 thru 12 three more times. This will result in the transmission being filled a total of four times.
14. After the transmission has been drained for the last time replace the drain plug gasket (PN 24 11 7 518 738) and torque the M18 drain plug to 40 Nm.
15. Refill transmission for the last time with 4.5 liters of BZL 799 oil. Check for correct oil level by removing the oil fill hose adapter - oil should flow slowly from the fill/level opening. Replace fill plug gasket (PN 24 11 7 518 710), and torque M14 fill plug to 21 Nm.
16. Install underbody splash shield.
17. Remove the short bolts and washers securing brake discs (to be reused on the next vehicle).
18. Check torque (27 Nm) of the brake disc retaining bolts.
19. Install front wheels and torque the retaining bolts to 120 Nm.
20. Clear DSC/ABS module fault memory with DISPlus/GT1.
21. Perform CVT transmission clutch adaptation as follows:
^ Engine and transmission must be at normal operating temperatures. Start the engine and apply foot brake.
^ Select and stay in "N" position for five seconds.
^ Select and stay in "D" position for three seconds.
^ Repeat this procedure five times.
^ Select and stay in "N" position for five seconds.
^ Select and stay in "R" position for three seconds.
^ Repeat this procedure five times.
PARTS INFORMATION
LABEL INSTRUCTIONS
This Service Action has been assigned code number 6. After the vehicle has been checked, and corrected if necessary, obtain a label (SD 20-013) and:
a. emboss your MINI dealer warranty number in the middle of the label (1);
b. punch out code number 6 printed on the label and,
c. affix the label to the B pillar as shown.
If the vehicle already has a label from a previous Service Action/Recall Campaign, affix the new label next to the old one. Do not affix one label on top of another one because a number from an underlying label could appear in the punched-out hole of the new label.
WARRANTY INFORMATION
Reimbursement for this Service Action will be via Campaign Entry
MINI RE-FUELING COST
MINI a Division of BMW of North America, LLC, will provide reimbursement to have the gas tank topped off once as required, for each vehicle affected by this service action. Attach the appropriate receipt to the work order.
RENTAL VEHICLES
Please note that SI M01 02 02 gives those participating MINI dealers the opportunity to self-authorize a rental vehicle if needed by your customer for this repair.
ATTACHMENTS
view PDF attachment M240102Letter.