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By Astonish Articles

 An automatic transmission is just that- automatic, consequently most people tend to pay very little attention to it until a major problem rears its ugly head.

Picture the scenario- you are driving along in the lap of luxury, the satellite radio blaring and the heated seats on. You have become accustomed to the comfort level and great driving experience brought to you by BMW.

You decide to stop at the local convenience store on your way home to grab some ice cream for the kids and a bottle of water for yourself. Upon returning to your car, you start it up, check your rear view mirror, put the shifter in reverse and then the unthinkable happens- the engine just revs as if it is in neutral and the car goes nowhere!

This article deals with the reasons behind an unexpected loss of reverse in certain BMW automatic transmission equipped vehicles, specifically the 3 series and 5 series vehicles that use the ZF5HP19 or steptronic transmission. This includes the popular 323i, 323ci, 325i, 328i, 330i, 525i, 528i, 530i, X3 and X5 models well as some others built in the 1999 to present model years.

To eliminate confusion, this does not apply to vehicles equipped with the GM 5L40 E transmission, just the ones with the sometimes problematic ZF5HP19. The 5L40 E has some issues of its own that are beyond the scope of this article but are certainly going to be the subject of another.

The failure rate for these transmissions seems to be very high and is expected to become much more of a problem as time goes by.

Typically, the vehicle is working perfectly while driving forward but when it is put in reverse there is a complete and permanent loss of movement to back up.

Reverse is typically a major feat for any transmission to accomplish- imagine the demands that are placed on a gearbox as it is asked to reverse the torque of your engine so that you can back up your nearly 4000 pound vehicle.

By far, the most common cause of the reverse problem in BMW’s is the failure of the D-G clutch drum. Specifically, the snap ring that retains the D or reverse clutch breaks out of the clutch drum resulting in an inability for the clutch pack to apply.

The good news is that there is hope in regards to a proper repair. The factory has released an updated part that so far appears to be a permanent fix for this problem.

In our testing and in conjunction with several hundred successful repairs at our facilities, the new part seems to be metallurgically superior in several ways.

We have found that there is an improved radius area as well as slightly thicker casting. In addition to this, the grove that retains the snap ring is also relocated further away from the edge of the drum.

With this issue addressed and attention to detail in several other areas of the ZF5HP19 unit, the transmission can be repaired to “better than new” condition by a competent transmission rebuilder / remanufacturer. In fact, when properly repaired, the ZF gearbox becomes quite robust and can provide an almost indefinite service life.

For more information on Car Transmissions or to find a Used Transmission visit SWTransmissions.com

Automotive System Integration Growth Advances
By Mike Trudel

 It doesn’t seem too long ago that the electrical system in a vehicle was mostly concerned with lights, starter motors, radios and windshield wipers. Those days are long gone. The automotive industry is currently realizing a dramatic increase of electronic equipment for onboard vehicle control. In modern cars, a variety of electronic control units (ECU) delivers sophisticated real-time control functionality.

In the automotive industry, there is little doubt that electronics growth will continue. To remain competitive, it is crucial to seamlessly integrate the new technology. Whether it’s an entertainment system, keyless entry, a back-up camera or touch screen navigation, the role of the automotive manufacturer is increasingly becoming that of a system integrator working closely with its suppliers.

There is a long tradition in the industry of working with suppliers, and a number of suppliers that exist deliver similar systems to vehicle manufacturers. Automotive suppliers are more than happy to fill the needs of manufacturers, and the ever increasing importance of electronics in automobiles brings with it a growing challenge and need for low-cost, reliable electronic systems. These systems are not isolated and must communicate with each other.

Historically, automotive electronics have relied on proprietary, dedicated wire communication schemes (at least for many sensor systems) and directly wired power outputs. This has led to excessive wiring, and wiring consumes space, adds weight and expense, and can be difficult to maintain.

Fortunately, advances in vehicle-networking standards are addressing these issues with the wide adoption of Controller Area Network (CAN) and Local Interconnect Network (LIN) architecture. These network standards are providing a balance between performance and cost optimization across automotive systems. CAN provides a high-speed network for chassis, powertrain and body-backbone communications, while LIN answers the need for a simple network for sensor and actuator subsystems that reduces cost and improves robustness through standardization. Together, the vehicle networking standards and advanced mixed-signal processes provide an opportunity for automotive manufacturers to introduce affordable new electronic systems as well as reduce costs. They also improve maintenance and reliability while providing advanced convenience and safety features, like collision avoidance.

The widespread adoption of CAN and LIN standards is an important development for automotive electronics and becomes much more significant in conjunction with recent advances in mixed-signal semiconductor processes.

Adopting standardized vehicle-networking architectures and using more highly integrated mixed-signal ICs bring several advantages at the system level. The first is an improvement in a system’s robustness and diagnostics. By adopting standardized networks for two-way communication, diagnostic and failure information can be obtained when there are issues with the system.

The second is a reduction in wiring requirements. Using standardized vehicle-networking architectures, it is possible to build a feature- and diagnostic-rich system that requires only three wires. Reduced wiring requirements have less cost, less weight, will be easier to install at the factory, and will help reduce the potential for failure.

Integration also leads to other advantages and savings. Printed Circuit Boards (PCBs) and housings can be smaller, allowing for improved and more flexible placement in the vehicle, with less concern about where and how to run the wires. Through the use of fewer components, there are fewer items to keep in inventory, qualify and monitor. Some of these factors also lead to a reduction in weight and space consumption, factors that are always important in vehicle design.

This advance is another step in increasing the intelligence and capabilities of automotive systems. We’re already witnessing this increased intelligence and capability with complex navigation systems, Internet access, passenger entertainment, ABS brakes, engine management systems and advanced stability control. The next generation of mixed-signal automotive integrated circuits (ICs) will integrate even more performance and processing power. It will provide programmable features and added flexibility that will be used to address the automotive electronic system needs of tomorrow. As these systems become more advanced, the possibilities are limited only by the applications that vehicle designers can imagine and that the end customer is willing to purchase.

Mike Trudel, Freelance Writer.

Delphi Corp. is poised to apply its expertise and know-how to provide vehicle manufacturers and consumers with in-vehicle entertainment and connectivity. To learn more about Delphi Corp., please visit www.Delphi.com/4Innovation or www.Delphi.com/4Connected.

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Today’s Automotive Engineer: A Technology Guru with Connectivity Solutions
By Mike Trudel

 Technology gurus are hiding in a variety of places these days. Say, for instance, the automotive industry.

The automotive industry has produced some of the most advanced and user-friendly technologies publicly marketed in recent years. We can now not only operate our cars without keys, but we can also map our next trip, download information from our desktops onto a “carputer,” assess the state of the vehicle, watch movies, arm a security system inside and out and be alerted when others are in our blind spots.

Take, for instance, an entry-level map-based integrated navigation radio, which uses a flash-based secure digital card color map database to provide high-performance navigation. A single, state-of-the-art navigation kernel and map data compiler used in the European market help shorten Original Equipment (OE) innovation cycles, and a range of options allows for entertainment and ease-of-use features. Integrated into a single unit, a map navigation system can be used in parallel to the audio system.

Such a system can include AM/FM radio, navigation tools, playback mechanisms like compact discs and MP3s, and connectivity options for portable electronic devices. Of course, customers can add nearly anything a techy heart could desire, like a digital tuner, USB, touch-screen interface, voice recognition, steering wheel control and audio codec options.

And that’s just the basic model. Touch-screen navigation radios are full-featured audio and navigation systems in one unit, using onboard computers that interact with the Global Positioning System (GPS), vehicle sensors and a DVD-map database. Such personal travel assistants minimize travel time, make travel more convenient and increase peace of mind. Benefits include multiple functions in one compact unit, the ease of a touch screen, voice prompts, entertainment options, state-of-the-art navigation, the ability to remap locations if the driver misses a turn and intersection views for detailed maneuvering guidance.

Active safety systems, like active night vision, lane departure warning systems and infrared side (blind spot) alerts, are other excellent examples of automotive engineers’ ability to connect advanced technologies in a manner that makes the driving experience both safer and more enjoyable.

Active night vision uses near-infrared headlamps to illuminate the road scene ahead and displays an enhanced image in the vehicle. This system provides high-beam visibility without blinding oncoming traffic. Components of the active night vision system can be shared with other safety features, such as a lane departure warning system.

When lane departure warning systems utilize a camera, the camera can also be used for multiple features, such as active night vision, pedestrian recognition, rain sensing and intelligent headlight control. The lane departure warning system uses a monocular camera mounted behind the windshield to track lanes in front of the vehicle. Accompanying software estimates lane width and road curvature, and determines the vehicle’s heading and lateral position within the lane. When the driver strays from his or her own “dotted lines,” an audible, tactile or visual alert is issued. According to an automotive magazine, ninety-five percent of all vehicular accidents involve some degree of driver behavior — such as swerving. Systems like lane departure warning provide hope of reducing the approximately one hundred deaths that occur every day on American roadways, as reported by the Public Broadcasting Service in 1995.

Side (blind spot) alerts provide the same hope. These systems help drivers be aware of vehicles in side blind spots when changing lanes and making turns. Sensors integrated into mirrors, taillights and side fascia measure the adjacent lane temperature over time to detect if vehicles are entering the side blind spot. If detected, the system provides visual indications within the mirrors. If this proves ineffective and a turn signal is activated anyway, an audible alert follows. These warnings give drivers more time to react and, hopefully, help avoid the more than 200,000 lane change accidents that occur every year according to the National Highway Traffic Safety Administration.

It’s amazing how easily they hide those geniuses of technology. We never hear their names, see their faces, or even, in most cases, acknowledge they exist. Yet it is the knowledge, safety and connectivity solutions of automotive engineers that are helping save lives and helping make sure the rest of us don’t get hopelessly lost on the way to that next great adventure — at least not too often.

Mike Trudel, Freelance Writer.

Delphi Corp. is poised to apply its expertise and know-how to provide vehicle manufacturers and consumers with in-vehicle connectivity. To learn more about Delphi Corp., please visit www.Delphi.com/4Connected.

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