2002 E500 Gearbox - Clunk when Engaging
 

Any ideas with the following problem....

E500 MY2003 4 speed auto, 60,000 miles. It had just started to go clunk (within 1 day), as you engage drive or reverse and it lurches forward (or backward). Its come on overnight and been doing it for the last 3 days.

At the same time, the car has started to hunt on very low throttle openings. I feels as if these should be un-connected symptoms, but they started at the same time.

Any advise welcome, or indeed anyone who can recommend an independent Merc garagein Leicester (orNorth Leicestershire).

Thanks in advance

Chris

RE: 2002 E500 Gearbox - Clunk when Engaging
 

722.6 is a 5 speed and if you have not had the fluid and filter changed it is due.Diy on mercedesshop.com diy section.MB spec fluid only.
also inspect flex discs for wear.
ohlord

RE: 2002 E500 Gearbox - Clunk when Engaging
 

Ohlord.... !!! Would you expect these symptoms just to start, as opposed to being gradual? and would what you suggest explain the hunting whilst driving on very low throttle?

Cheers

Chris

RE: 2002 E500 Gearbox - Clunk when Engaging
 

The problem got worse last Monday and the ignition lamp came on.

Its been into Mercedes and the cooler matrix has failed. Apparently it shares the matrix with the Engine cooling (but seperate systems). If one fails it can leak into the other. The transmission fluid has been contaminated with coolant, hence the problems.

The fix is a new matrix, flush both engine coolent and transmission systems and replace fluids. The extended warranty will pay for the parts but the the flushing and fluids. They pay £900, I have to pay £500.

I'm told that they have seen this before a number of times. This is on the CURRENT model E500 (MY 2003).

Cheers

Chris

RE: 2002 E500 Gearbox - Clunk when Engaging
 

Ohlord, I guess you were correct. Transmission fluid, albeit due to a failed shared cooling matrix, thanks.

Have you heard of the matrix failures before?

The cost to fix sounds expensive (~ $2500) but at least I have an S class (brand new)as a loan car!!!!!

RE: 2002 E500 Gearbox - Clunk when Engaging
 

o3 E500 had the valeo radiator and it had a defect that could leak coolant into the trans.In the states they had a tech service bulletin and I think some kind of recall.I hope a flush works and the trans is not shot,either way they know of the problem and if you nicely complain to mb europe and dealer management you might get them to foot the complete bill.
ohlord

RE: 2002 E500 Gearbox - Clunk when Engaging
 

Thank Ohlord..... just found this:

The transmission oil cooler of automatics is sited in the radiator matrix, so failure can lead to coolant entering the transmission and destroying it, leaving the owner with a bill of £4k - £6k. MB responded that this fault only occurred in cars manufactured between 2000 - 2003 and only when a Valeo radiator is fitted, but has occurred in later cars. By August 2008 there was an epidemic of failures with fresh reports every couple of days, dealers quoting £11k to fix and MB usually refusing to pay which effectively writes off a 2003 E Class as scrap. Also affects 2004 registered E Class.

RE: 2002 E500 Gearbox - Clunk when Engaging
 

I'm thinking that the initial fault was present when Ipurchased the car (from MB main daler) June 2007. I had complained for it being hard to pull away smoothly, in fact i've just found the letter I sent them and it says, quote:

"Surging on initial throttle travel. It is hard to pull away smoothly at times. Periodically, the car will rapidly accelerate when pulling away from stationary. It only happens occasionally, but it is very disconcerting and possibly dangerous"

Although I thought it was a trottle issue at the time, I'm thinking it was probably the gearbox (the sympton was like a learner driver in a manual gearbox giving too many revs and then letting out the clutch too quick). They never fixed it and I just lived with it (became sensitive to it), to this day my wife will not drive the car because of it.

From whatohlord saying is that MB knew of the radiator issue and a tech bulletin was suggesting they test the transmission fluid if they suspect a problem.

Do you thik the symptom above (in July 2007) relates to the valeo radiator failure?

If so, do you feel they should have check the fluid back then and 'caught' the problem back then? and more importantly when it was still in warranty (1 year MB used car warranty)?

Cheers

Chris

RE: 2002 E500 Gearbox - Clunk when Engaging
 

Yes,they should have checked it.It is a known issue and the symptoms you complained about were exactly how the issue raises its ugly head.That trans is toast now,and i doubt any amount of flushing can save it.Call MB and complain,nicely.
ohlord

Just though I advise the outcome....

The problem was the Valeo radiator. I had it replaced and a tranny fluid flush.

Some 9 months later an it drives OK, but I'm left with a clunk as you engage drive or reverse, especially from cold. In fact you have to make sure you are heavy on the brake as you engage drive, else you'll jump forward as it 'kicks' in.

The other symptom that never went away, was that the parking brake is not strong enough to hold the Car whilst in drive, plus it will creep up a local hill (that has traffic ligts on it) when previously (before the problem) it whould 'hold' its self on the hill.

Any ideas on these two symptoms.... do any of you think thay may be related to the orginial problem?

Torque converter perhaps (this was not changed, despite the MB service bulitin saying it should have been, the MB dealership said they thought it was OK).