[Wheelwright]

So, about 6-months after my gearbox was replaced the symptoms are back: grinding in 2nd gear unless making slow, deliberate shifts. I know Honda used to have similar problems but I expected more from BMW which costs twice as much and its gearbox was advertised as "borrowed from upcoming M3/M4".

[ocN55]

hm not good.. keep updating OP

[2msport]

dang goodluck.. Not sure about Canada but 3 times gets you a lemon law in California. Full money back. I've heard a number of cases where BMW just directly replaced the car so you don't have to go through the courts.

[Wheelwright]

I think it is only applicable if they can't fix an issue after 3 consecutive attempts. In my case that's not technically correct: they fixed an issue on first attempt by replacing the gearbox, the problem is that those gearboxes tend to only last about 6-months. And before you say I don't know how to drive I drove daily Focus SVT for 8 years and then 128i for 4-years and never had a gearbox issue requiring a complete replacement.

[Wheelwright]

So my dealer's foreman is denying there is a problem because even though he heard me grinding the transmission a month ago today he claims he cannot replicate it himself (he shifts slowly and barely knows how to use a manual transmission). Word of explanation: there was a month delay because back then I was told I must setup a new appointment for them to check it out and it took one month for a loaner to become available.

[overcoil]

Can you make a cell phone vid of the grind so this forum can listen ?

[tccox]

Well, I've had my 228 manual for over a year and 11,000 miles with zero issues with the 1-2 shift. Wonder if it could be a clutch related ? Doesn't make sense that two trans could go bad in six months. Some other issue causing the trans to fail ? Wierd


Edit. Sorry just noticed you have a 235. Must be all that extra power

[Wheelwright]

Originally Posted by tccox

Doesn't make sense that two trans could go bad in six months. Some other issue causing the trans to fail ? Wierd

Actually each of those transmissions lasted about 6 months. Now the dealer is very reluctant to replace the second one even though I already replicated the grind a month ago (the foreman acknowledged it then as he sat next to me).

I will try to repeat the problem again tomorrow morning to have it in writing, this time they assured me it will actually count as "problem replication" in their documents after I pressed them on the issue.

I am surprised they themselves can't replicate it because even my brother was griding 2nd gear when he tried to shift M235i the way he does his 12-year old Mazda 3. Or maybe they say they can't replicate it only to protect BMW because two failed trannies in a row makes the manufacturer look bad.

[Wheelwright]

I had an illuminating conversation with my service manager today (an approachable and courteous guy BTW). It turns out BMW already had "several" failed 6MT transmissions in the USA so they are starting to investigate their supplier (I assume BMW outsources manufacturing to ZF but I may be wrong). BMW wants to know if their supplier's manufacturing processes are up to par and in particular if the molds they use are within specs.

In view of the above my service manager told me the transmission will be replaced for the second time pending BMW tech actually being able to replicate the problem that I have (2nd gear grind and vibration when engaged relatively quickly). I guess time will tell if BMW will institute a mass recall or if it is an isolated problem. Or maybe a secret TSB will be established to address this issue ?

[Wheelwright]

The dealer said my clutch components are broken and they want me to pay more than $4,000.00 (four thousand) dollars to replace them. My car only has 25000km on it (it is about year and a half). The car has transmission and everything removed so it is struck. I never abused my car, never did a burnout, never dumped the clutch and I rev-match every time.

Any advice on how to proceed would be greatly appreciated. Thanks in advance.

[Luftwaffe1O1]

Originally Posted by Wheelwright

The dealer said my clutch components are broken and they want me to pay more than $4,000.00 (four thousand) dollars to replace them. My car only has 25000km on it (it is about year and a half). The car has transmission and everything removed so it is struck. I never abused my car, never did a burnout, never dumped the clutch and I rev-match every time.

Any advice on how to proceed would be greatly appreciated. Thanks in advance.

Well I would firstly yell at the service manager. Tell him you have complained about this for almost a year now. (I assume there are records of you complaining about transmission issues right?)

So point to him that you had been having these issues, and the techs said there is no problem. Now there is a problem... they didn't look into it.

if they refuse, contact BMW NA, if they don't get you far, contact a lawyer. I guess the one thing in your favor here is that there is a fairly long paper trail of you complaining about this.

But the biggest curiosity is that even the 2nd tranny started failing after 6months. That's odd.

[abirmaher]

Originally Posted by Ritz42

Does make a weird power drillish sound and still go into gear? Or does it just grind and not go in? If its the first, you've got a bad syncro/transmission.

I'm in this boat unfortunately. Going in for service next week hopefully I can convince them of the issue as it is intermittent.

[alexc93]

I had this on my previous 135i but with 1st gear, was going to be like $6k to replace.

[abirmaher]

Any updates?

[Wheelwright]

At 25000km I had clutch and flywheel replaced for which I paid about $4800.00. Long story short: My dealer said that the gearbox grind was caused by clutch not disengaging quickly enough (due to it being worn out) which overstressed the synchro.

This bad clutch didn't even slip though because there was still some material remaining so I find it absolutely horrifying that a perfectly functioning clutch, however worn, can cause gearbox grind which in turn can destroy that gearbox (once the synchro is gone the gearbox is gone).

Also, if the gearbox grind was really caused by the clutch not disengaging quickly, why did I only have problems in 2nd gear ? Clutch works exactly the same for all gears therefore all gears should be affected.

The bottom line is: I still don't know what's going on.

Of course, despite dealer's assurances to the contrary, the gearbox still grinds after all those clutch components were replaced, however for this past year I adjusted my shifting to slow down any 2nd gear engagement.

Also I don't downshift into 2nd above 2500-rpm any more knowing how fragile my car is and that if anything goes wrong I will likely be taken to the cleaners again as I was with this bad clutch despite me never riding or dumping clutch, never using launch control etc. etc. There are many people who do those things on a regular basis and their clutch still lasts over 100000km.

I suspect that in my case I got bad parts or something was improperly installed or adjusted at the factory for which I am now made to pay.

[delvec03]

your whole situation is absurd. my Rx8 had grinding gears (multiple synchro failures multiple times due to 9k red line ?) and they covered it under warranty.

if it keeps happening I'd suggest they keep replacing parts. get a lawyer. I shift 1-2 at 6500 rpm like butter. in fact, its almost like the car WANTS me to shift faster.

get lawyer and your money back and a new tranny.
?

[Luminous]

Wow sorry to hear you're going through this! I don't understand how they can deny warranty without proving it was user error? Especially when this is kind of a known issue with these trannies? Can't they pull data from the ecu to see if the car was abused?

[kyoko]

I have a 335i and had grinding issues shifting into 2nd like you described. It was replaced under warranty. The tech said that there are a few cases of the syncro's having issues and needing replacement.

There must be BMW of CA that you can talk with or something. That just doesn't sound right. Have you tried taking it to another dealer?

[Pray for Mojo]

Those clowns should have replaced the clutch when they did the transmission the first time around. You shouldn't have paid a dime for any of the work.

[abirmaher]

Update on my end. I finally found time to take my car in. I ordered a new clutch and flywheel as I was having club slip as well and figured if I was going to take it in for this maybe I could have them swap those parts at the same time. Plus seeing as how expensive Bmw seems to think their clutches are I could get way more clutch for the money from another source.

Ended up going with a clutch masters fx350 street/race clutch which I am very excited for.

Anyways I dropped the car off yesterday and got confirmation today that it seems like Bmw will be replacing the transmission. Should have a time line soon and hopefully when I get it back the issues I have been seeing are resolved.

[Wheelwright]

Good news: I just received a call this afternoon that BMW has authorized a manual transmission replacement (this will be my 2nd replacement). I appreciate they are finally doing the right thing after so much ordeal: BMW is back on my list of possible future cars.

However, after what I have been through I will never push this car anywhere close to "performance driving" (not that I did in the past but I wasn't driving it like Prius either). In practical terms this means giving it at least 1-second pause between 1st and 2nd gear when accelerating in a spirited fashion.

I know if I execute that shift the way Honda or Porsche drivers routinely do without a second thought, I will destroy another transmission. As I learned the hard way one shift is all it takes in my car. This scares the crap out of me because, at least in Canada, BMW charges Ferrari prices if anything goes wrong and you're deemed at fault.

[B_Rice]

Are you depressing the clutch all the way to when you shift? I've found out that the grab point is pretty much anything above the floor.