5L40E Master Rebuild Kit 2002, new and ready to install. Fits the 5L40E. Ships fast from the USA.
If your 2002 BMW six-cylinder with the GM-built five-speed automatic has started to flare between gears, sit a beat before it takes Drive or Reverse, or leaves dark fluid and friction dust on the pan magnet, the clutch packs are telling you they are done. This is a new Raybestos master rebuild kit for the 5L40E, cataloged for 2002-on units, with the friction plates and the full sealing package needed to overhaul the transmission once instead of fixing it a piece at a time.
There is no separate steel plate set, and that is by design. The 5L40E and 5L50E clutch packs use single-sided frictions that run against each other, so a complete set of frictions is a complete clutch rebuild for this unit. A filter is not part of the kit; plan on adding one.
The 5L40E is a longitudinal, rear-drive five-speed GM assembled in Strasbourg, France. Its gears come from a single Ravigneaux planetary set, so every ratio from 3.42 first to 0.75 fifth depends on the right combination of clutches and one-way sprags holding at the right time. GM rated it for engines up to about 250 lb-ft. When one pack loses apply pressure through a hardened piston seal or a worn sealing ring, that clutch slips during the overlap, heats up and contaminates the fluid that the rest of the unit and the valve body depend on. Replacing every friction and every seal together brings all five ranges back to the same starting point.
Not every 5L40E complaint is worn frictions. Transmission Digest documents a 1-2 bind-up caused by a stuck safety-mode valve in the valve body, plus reverse, direct and coast clutch failures traced to worn pump sealing rings and a cracked direct/reverse housing. A kit fixes the rings and frictions, not a cracked housing, so inspect it during teardown. Before you commit, check the fluid and scan for codes, then work through our transmission slipping diagnosis guide. Clean red fluid with a harsh or erratic shift usually points to the valve body rather than the clutches.
This listing is the 2002 version, and the kit is cataloged for 2002-on 5L40E transmissions. In 2002 that means BMW cars: BMW calls this unit the A5S360R, and it was used behind six-cylinder engines in the E46 3 Series, E39 5 Series and Z3. Cadillac, Pontiac and Saturn adopted it later. BMW also fitted ZF automatics in other models, so confirm what is in your car first. Transmission Digest places the ID tag on the left rear of the case just above the pan rail, and BMW tags carry a G or Z code. If your car is a 1999-2001 build, or you are unsure, send us the year and VIN before ordering. Related parts for the 5L40E and its heavier 5L50E twin are on our 5L50E and 5L40E parts page.
| Fits | 5L40E 2002 |
| Part type | Master Rebuild Kit |
| Condition | New |
| Brand | Raybestos |
| Ships | From the USA |
| Warranty | 1-year |
No, and none are needed. The 5L40E and 5L50E use single-sided friction plates instead of a friction and steel stack, so the full set of frictions in this kit covers every clutch pack.
If the car has the GM five-speed (BMW A5S360R), yes, the kit is cataloged for 2002-on 5L40E units. Check the tag on the left rear of the case above the pan rail, or send us your VIN and we will confirm.
The kit is built for the 5L40E and 5L50E family. The 5L50E is the heavier-duty version used with the Cadillac 4.6L and in some AWD BMWs, so confirm your unit and send the VIN if in doubt.
No. The kit covers frictions, seals, sealing rings, O-rings and gaskets. Add a new filter and pan gasket so contaminated fluid from the old clutches is not drawn back through the rebuilt unit.
Inspect the pump, drums, sprags and the direct/reverse housing during teardown. Any cracked or scored hard part has to be replaced, and the valve body should be cleaned and checked since debris can stick its valves.
Fill with the fluid your vehicle specifies, check the level hot through the fill plug, and reset the transmission adaptives with a capable scan tool so shift timing relearns on the new clutches.
