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      02-24-2020, 12:25 AM   #1
Theodore
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DIY: Fix the DCT Fluid Weeping Problem (Mechatronics Harness O-Ring)

Warning: This DIY requires very long arms, I found it barely reachable with a 6 foot arm span.

A tiny, overpriced O-ring (BMW Part# 28607849555) at the top of the DCT slowly fails:





DCT fluid seeps past the failing O-ring on the top of the transmission where the DCT wiring harness plugs into the DCT mechatronics unit:



Which then pools in the crevices of the DCT structure, but it eventually drips down the side of the DCT transmission:



And creates a weeping effect:



On eBay, it seems nearly every E9X M3 DCT transmission that has not been cleaned up prior to photographing shows signs of fluid leaking past this mechatronics harness O-ring.





Unlike other BMW Getrag DCT transmissions, we don't have to change out the entire Mechatronics sleeve (as seen in some videos online for other BMW's with DCT transmissions) in the E9X M3 DCT as it has a replaceable o-ring on the Mechatronics sleeve (BMW Part # 28607849555).

1. You need to raise all 4 corners of the car for this repair.

2. Remove the exhaust on your car. First remove the rear section of the exhaust (see the Axle-Back DIY Exhaust Removal from shiblanor)


and remove the mid-section of the exhaust as well (see the Fabspeed X-Pipe DIY Install from jo8M3)


3. Remove the heat shields covering the DCT and the driveshaft.

4. Support the bottom of the DCT with a jack and remove the DCT support bracket.



5. Disconnect the driveshaft from the rear of the DCT transmission and support the driveshaft out of the way, but in a manner that keeps it relatively parallel to the differential.

6. Using the jack under the DCT, slowly lower/tilt the rear section of the DCT downwards.



7. Using very long arms reach in and disconnect the DCT wiring harness from the mechatronics sleeve. This is done using a counter-clockwise turning motion of about 1/4 of a turn on the outer plastic wiring harness where it connects to the mechatronics sleeve.



8. Insert the temporary protective cover over the exposed mechatronics sleeve electrical prongs (BMW part # 83300494213).





9. Thoroughly clean the exposed portion of the mechatronics' sleeve and the surrounding area. I used brake cleaner sprayed onto a rag to avoid over-spray onto the wiring or possibly into the DCT.

10. Remove the machine screw (T27) holding the mechatronics sleeve in place.



11. Pull the mechatronics sleeve out of the DCT by approximately 2 inches exposing the mechatronics harness O-ring.



12. Very carefully, using a pick or similar tool, remove the mechatronics harness O-ring by sliding it over the mechatronics sleeve towards you (towards the rear of the car). The O-ring is flexible enough to go up and over the "arm" that the T27 bolt sits in.



13. Place the replacement mechatronics harness O-ring on to the mechatronics sleeve back into the same location being careful to position the tallest end of the O-ring on outwards (towards the rear of the car). The new O-ring will stretch up and over the "arm" that the T27 bolt sits in without deforming.



14. Reassemble everything in reverse order.

Sources for this DIY

Borrowed images and ideas from this page.

BMW TIS which states you must fully remove the DCT from the vehicle to complete this job.
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Last edited by Theodore; 02-26-2020 at 09:06 PM..
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      02-24-2020, 01:49 PM   #2
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How did you look up there to confirm it was that and not the mech cover weaping?
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      02-24-2020, 05:14 PM   #3
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I noticed it when I removed the driveshaft for other work. Even without lowering the transmission, if you have the heat shields off you can use your phone in conjunction with a work light to see the fluid pooled up or you may be able to reach your hand up there and feel the fluid sitting on top of the DCT. My suspicion is this leak is commonly misdiagnosed as a failing mechatronics side cover gasket or DCT pan/pan gasket.
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      02-26-2020, 10:38 AM   #4
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Impressive work here!
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      02-26-2020, 11:20 AM   #5
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To bad there isnt an upgraded O-ring to replace the failure prone rubber one...
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      02-26-2020, 01:42 PM   #6
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Thanks a lot! Great work OP. I am assuming the answer is yes, but I take it the O Ring is flexible enough to go up and over the "arm" that the T27 bolts through?

Also the TIS warns of potential damage if the area is not cleaned thoroughly. After you put the protector sleeve in, what did you use / do to clean the area?
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      02-26-2020, 06:29 PM   #7
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Thx for this OP!

$30 for an O-ring?!?

Admins - can we sticky this?
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      02-26-2020, 06:32 PM   #8
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How come the o-ring is on one side, in pic #11, but on the other side in pic #13?
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      02-26-2020, 06:35 PM   #9
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Quote:
Originally Posted by da jemster View Post
How come the o-ring is on one side, in pic #11, but on the other side in pic #13?
cuz its mid-install, and highlighting make sure the orientation is correct before installing all the way.
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      02-26-2020, 09:10 PM   #10
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Quote:
Originally Posted by For3 View Post
Thanks a lot! Great work OP. I am assuming the answer is yes, but I take it the O Ring is flexible enough to go up and over the "arm" that the T27 bolts through?

Also the TIS warns of potential damage if the area is not cleaned thoroughly. After you put the protector sleeve in, what did you use / do to clean the area?
Yes, it stretches over the bolt arm with a little finesse, but not so much that it damages the O-ring. I used brake cleaner sprayed onto a rag to avoid over-spray onto the wiring or possibly into the DCT. Added both notations to the original post, thanks.
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      03-05-2020, 12:27 AM   #11
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The E9X M3 DCT can be lowered a bit. Can I replace the mechatronic side cover Gasket?
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