Hi, my E60 has over 230,000 miles now, and I've noticed a quiet motorcycle-like chattering sound in lower gears, when starting from a stop. It's not the exhaust rattling. It's been going on for a about a year, and it goes away after about 3rd gear. Lately though, I also hear and feel knocking in lower gears, which again, goes away in higher gears. I have an automatic and the shifting from lower gears is not that smooth either, especially during the cold months. Is this probably the clutch? I'm debating whether I should invest any more into this car, but at an indie shop, on average, how much is clutch replacement?

 

I'm having a similar problem at 135,000 miles with lower gear shifts that aren't as smooth as they used to be. If your trans & diff fluid has never been changed, that would certainly be the firs thing that I would do. It could also (in addition to dirty fluid) be the solenoid valves in need of replacement. It comes a kit and isn't terribly expensive for the part. A fluid change at my indie was $300. Still too high but not nearly as bad replacing the transmission.

 

I would first attempt to replace the valves or mechatronic unit. As the pistons wear out the fluid could leak by them a bit and I would think it wouldn’t shift as well. I personally haven’t really heard of the clutches wearing out so I would tend to think the fluid pressure behind the clutches is the problem. Take with a grain of salt as I’ve never owned a slushbox myself.

 

UPDATE AND SOLVED: I spent quite some time and money on changing the solenoid valves, all seals and mech sleeve, pumping in new oil. Reset adaptations. That didn't solve anything. I finally took her to the mechanic, who diagnosed the problem as soon as he accelerated. Failed drive shaft bearing. I had them put in a whole new drive shaft, only couple hundred bucks for the labor (plus the cost of new driveshaft). It now drives flawless. I guess I didn't have to do anything with the transmission after all, but I'm glad I did, it's good for the car anyway.

 

that explained why it goes away in higher gears

 

I was gonna read the entire post before I replied, because I figured the problem was gonna be the drive shaft bearing. I had the exact same problem with my '1995 525i, manual tranny. It felt just like the clutch needed to be replaced...shuttering when starting out, just as described here. New drive shaft fixed it!