1994 JAGUAR XJ6 brake

Manual Transmission & clutch (AJ16)
I Molykote FB 180 grease
Brake (clutch) fluid
- minimum
DOT 4
Dexron IID Transmission oil
Loctite
573
Tivoli Kay Adhesives No. 5696
Withdrawal arm pivots / Gearshift lever ball
Clutch hydraulic system
Front cover securing bolts
Exhaust sealer also used
in
ZF automatic
transmissions
Application
Material removal to clean up clutch face
IU SERVICE DATA
Specification
Up to lmm maximum
X300 VSM iii Issue 1 August 1994

Manual Transmission & Clutch (AJ16)
7.1.12 CLUTCH, DESCRIPTION
The single-plate, diaphragm-type clutch, is operated by the pushrod of the slave cylinder acting on the clutch lever.
The slave cylinder, mounted on the transmission bell housing, is operated hydraulically from the clutch master cylinder
through
a series of hydraulic pipes.
The piston in the master cylinder is operated
by a push rod from the clutch pedal, which is fitted to the bulkhead
mounted pedal box.
The clutch pedal is positioned to the left of the brake pedal.
The engines use
a twin-mass flywheel configuration with built-in springs to provide a smooth take-up of drive.
The flywheel is extremely heavy and great care must be taken when lifting
it from the vehicle.
Fig.
1 The Clutch Assembly
CAUTION: The hydraulic fluid used in the clutch hydraulic system is injurious to car paintwork. Utmost precautions
MUST at all times be taken to prevent spillage of fluid. Should fluid be accidentally spilled onto the
paintwork, wipe fluid off immediately with a cloth moistened with denatured alcohol (methylated
spirits).
Issue 1 August 1994 X300 VSM

Manual Transmission & clutch (AJ16)
7.1.15 CLUTCH MASTER CYLINDER, RENEW
SRO 33.20.01
. Remove the clutch master cylinder to clutch pedal clevis
pin securing clip (1 Fig. I), and remove the clevis pin (2
Fig. 1).
. Remove the master cylinder securing nuts (3 Fig. 1).
. Disconm.the hydraulic pipe (4 Fig. 1) from the master
cylinder, and fit blanking plugs to the pipe and master cy- linder.
. Remove the master cylinder assembly (5 Fig. 1) and the
gasket (6 Fig. 1).
. Fit the new master cylinder to the bench vice and fill the
reservoir.
. Refit the reservoir cap.
. Remove the blanking plug from the master cylinder.
. Prime the master cylinder by 'working' the push rod until
fluid appears at the hydraulic pipe outlet.
. Remove the master cylinder from the vice.
. Place a new gasket (6 Fig. 1) over the mounting studs.
. Fit and align the master cylinder assembly to the studs,
. Remove the blanking plug from the hydraulic pipe (4 Fig.
. Ensure that the union is clean and no foreign matter enters
and secure
with the nuts
(3 Fig. 1).
1 ).
the system.
WARNING: USE ONLY CLEAN BRAKE FLUID OR DENA- TURED ALCOHOL (METHYLATED SPIRITS) FOR
CLEANING. ALL TRACES OF CLEANING FLUID
ALL COMPONENTS MUST BE LUBRICATED
WITH CLEAN BRAKE FLUID AND ASSEMBLED
USING THE FINGERS ONLY.
MUST
BE REMOVED BEFORE RE
-ASSEMBLY.
. Reconnect the pipe (4 Fig. 1) to the master cylinder (5 Fig. I), and tighten the union nut.
. Align the push rod to the pedal.
. Clean and grease the clevis pin (2 Fig. 1).
Align andfit the clevis pin to the pedal and push rod.
. Fit the securing clip (1 Fig. 1).
. Bleed the clutch hydraulic system, see Sub-Section
7.1.18.
-4
1
J33 072 2
Fig. 3
issue 1 August 1994 16 X300 VSM

Manual Transmission & Clutch (AJ16)
e
7.1.16 CLUTCH SLAVE CYLINDER, RENEW
SRO 33.35.01
. Disconnect the pipe from the clutch slave cylinder, plug or
tape the pipe to prevent the ingress of any dirt.
. Remove the nuts (1 Fig. 1) and spring washers securing
the slave cylinder to the transmission.
. Remove the hose clip bracket (4 Fig. 1) complete with the
hydraulic hose/ pipe (5 Fig. I), and slide the slave cylinder (2 Fig. 1) off the mounting studs.
. Slide the rubber boot along the push rod (3 Fig. 1) and
withdraw the push rod from the cylinder.
. To refit the new clutch slave cylinder, reverse the removal
operations.
. Bleed the clutch hydraulic system, see Subsection
7.1.18.
Fig. 1
7.1.17 CLUTCH SLAVECYLINDER, OVERHAUL
SRO 33.35.07
. Remove the clutch slave cylinder, see Sub-Section 7.1.16.
. Dismantle the cylinder. The new parts in the kit will indicate which used parts should be discarded.
. Clean the remaining parts and the cylinder thoroughly with unused brake fluid of the recommended type and place
the cleaned parts on to a clean sheet of paper.
WARNING: USE ONLY CLEAN BRAKE FLUID OR DENATURED ALCOHOL (METHYLATED SPIRITS) FOR CLEANING.
ALL TRACES OF CLEANING FLUID MUST BE REMOVED BEFORE RE-ASSEMBLY. ALL COMPONENTS
MUST BE LUBRICATED WITH CLEAN BRAKE FLUID AND ASSEMBLED USING THE FINGERS ONLY.
. Examine the cylinder bore and the pistons for signs of cor- rosion, ridges or score marks. Provided the working sur- faces are in perfect condition, new seals from the kit can
be fitted, but if there is any doubt as to the condition of the
parts then a new cylinder must be fitted.
. Fit the new seal (1 Fig. 2) to the piston (2 Fig. 2) with the flat
back of the seal against the shoulder.
Lubricate theseal and thecylinder bore with unused brake
fluid of the recommended type and assemble thecylinder.
. Before fitting the dust cover (3 Fig. 21, smear the sealing
areas with rubber grease.
Squeeze the remainder of the grease from the sachet into
the cover to help protect the internal parts.
. Refit the clutch slave cylinder, see Sub-Section 33.15.01.
Bleed the clutch hydraulic system, see Sub-Section 7.1.18.
U 111 "I, II
Fig. 2
-3
X300 VSM 17 Issue 1 August 1994

Manual Transmission & Clutch (AJ16)
7.1.18 CLUTCH HYDRAULICSYSTEM, BLEED
SRO 33.15.01
CAUTION: Only use minimum DOT 4 brake fluid in the hy- draulic system.
. Remove the reservoir filler cap, and top up to the correct
level with hydraulic fluid.
. Attach one end of a bleed tube (1 Fig. 1) to the slave cylin- der bleed nipple (2 Fig. 1).
. Partiallyfill a clean container (3 Fig. 1) with hydraulicfluid.
. Immerse the other end of the bleed tube in the fluid.
. Slacken the slave cylinder bleed nipple.
. Pump the clutch pedal slowly up and down, pausing be-
. Top up the reservoir with fresh hydraulic fluid after every
tween
each stroke.
three pedal strokes.
CAUTION: Do not use fluid bled from the system for top- ping up purposes as this will contain air. If the fluid has been in use for some time it should be discarded. Fresh fluid bled from the system
may be used after it has stood for a few hours
allowing
all the air bubbles to disperse.
Pump the clutch pedal until the pedal becomes firm,
a Top up the reservoir, refit the filler cap.
tighten
the bleed nipple.
. Apply working pressure to the clutch pedal for two to three
minutes and examine the system for leaks.
X300 VSM Issue 1 August 1994 18
Fig. 1

Automatic Transmission (AJ16)
Both types of automatic transmission comprise a hydrodynamic torque converter driving an epicyclic gear train which
provides four forward ratios and reverse. Gearshift selection is made by a hydraulic (or electronichydraulic) trans- mission control unit. Six gearshift positions are provided:
Position
'P' (Park) -the driven wheels are mechanically locked at the transmission.
Position
'R' (Reverse) - reverse gear selected.
Position
'N' (Neutral) - engine disconnected from drive-line and wheels.
Position 'D' (Drive)
- all four speed ranges are selected automatically with lock-up available in top gear only.
Position
'3' - automatic selection of the lowest three speed ranges only.
Position '2'
- automatic selection of the lowest two speed ranges only; the transmission is prevented from shift- ing up to the third and top speed ranges.
Immediate selection of a lower ratio is also available, within mapped limits, by 'kick
-down' (pressing the accelerator
pedal down beyond the normal full throttle position) for example when overtaking.
A brake pedal/gearshift interlock is incorporated in the shift lever mechanism. Theshift lever may only be movedfrom
the 'P' (Park) position if the ignition key switch is in position 'll', and the foot brake is applied. The ignition key cannot
be removed from the ignition switch unless the shift lever is in the 'P' (Park) position. Once the ignition key has been
removed, the shift lever is locked in the Park position. The gearshift interlock may be over-ridden manually in the event
of an electrical failure or when it is required to move the vehicle manually for access, ie for removal of the propeller
shaft.
8.1.1.1
Gearshift selection causes the appropriate gear to be selected through a cable operated shift lever on the side of the
Gear Selection (ZF 4HP 22)
transmission unit. When a gea; is selected, the shift points are determined by accelerator pedal position through a
throttle cable connection and by pressures equivalent to road speed derived from a centrifugal governor on the output
shaft.
Gearshift speed and quality are controlled by the hydraulic control unit located in the lower part of the transmission
housing. The control unit contains selector valve, control pistons and pressure valves.
The hydraulic control unit can be overridden by 'kickdown'. This is actuated by the final travel of the accelerator pedal
and causes the next lower gear to be selected.
8.1.1.2
Gearshift selection causes the appropriate gear to be selected through a cable operated shift lever on the side of the
transmission unit; the shift lever also operates a rotary switch attached to the side of the transmission unit. When a
gear is selected, the rotary switch provides an output or combination of outputs to the TCM, which continuously moni
- tors the gear selected in addition to output shaft speed and transmission oil temperature. Information from the Engine
Control Module (ECM) representing engine speed, load and throttle position is also fed to the TCM to enable the most
suitable gear to be selected.
Gear selection and gearshift speeds are controlled by the manually operated selector valve, a solenoid operated pres
- sure regulator and three solenoid valves. On receipt of signalsfrom the TCM, the three solenoid valves MVI, MV2 and
MV3, in various combinations with the safety valve, determine the appropriate gear range. The TCM, on receipt of
information of engine state and road speed, determines the shift speed.
The Performance Mode switch, located on the shift lever surround, provides two alternative shift speed patterns:
1. 'Normal (Economy) Mode' - designed for everyday use.
2. 'Sport Mode'
- gear shift takes place at higher road speeds to enhance performance.
The 'kick
-down' switch, located beneath the accelerator pedal, is actuated by the final travel of the pedal and signals
to the TCM that the next lower gear is to be selected.
Gear Selection (ZF 4 HP 24 E)
X300 VSM 3 Issue 1 August 1994

bZF Automatic Transmission (AJ16) -
0
8.1.2 TRANSMISSION FLUID, RENEW
SRO 44.24.02
= Raise the hood and fit a fender cover.
. Raise the vehicle on a ramp.
. Place a drain tin in position beneath the transmission drain
Release and remove the transmission drain plug; allow
. Fit the drain plug with a new washer and torque tighten.
Reposition the drain tin beneath the dipstick tube union.
Remove the screw securing the dipstick tube bracket.
. Release the dipstick tube union nut and disconnect the
tube from the fluid pan.
. Drain the transmission fluid.
Clean the tube unions, reconnect the dipstick tube to the
. Lower the vehicle on the ramp.
. Remove the transmission dipstick.
. Renew the transmission fluid filter, see Subsection 8.1.6.
Fill the transmission with the correct fluid, see the ZF Auto-
Note: It will not be possible to get all the initial fill quantity
of fluid into the transmission.
. Refit the dipstick.
. Startthe engine, apply all brakes and run the transmission
With the engine still running, remove the dipstick.
Clean the dipstick and refit.
Remove the dipstick and check the transmission fluid
. Add fluid until the correct level is achieved.
. Stop the engine and refit the dipstick.
. Checkfluidleveltothe'HOT'marksaftera20mileroad run
(3,2L AND 4,OL)
Plug.
the fluid to drain.
fluid pan and torque tighten the union nut.
0
matic Transmissions Service Manual, General Data.
through
all gear positions and select 'Park'.
level. Remove the fender cover and lower the hood.
to ensure accurate results.
m
e
0
X300 VSM Issue 1 August 1994 6

Automatic Transmission (AJ16)
8.1.5 TRANSMISSION ROTARY SWITCH, RENEW
0 (4,OL)
SRO 44.15.36
. Check the shift cable adjustment.
. Switch the ignition ON, apply the footbrake and move the
Switch the ignition OFF and disconnect the battery.
. Open the armrest lid.
. Release and remove the ashtray securing screws.
. Displace the ashtray assembly for access.
. Disconnect the cigar lighter / illumination harness con-
. Place the ashtray assembly aside.
. Displace and remove the console veneer panel rear fin-
isher.
Carefully displace the Performance Mode switch from the
gear surround finisher.
. Disconnect the Performance Mode switch from the har-
ness multi-pin plug.
Displace and remove the Performance Mode switch sur-
round finisher.
Displace and remove the shift lever surround finisher.
. Release and remove the veneer panel wing nuts.
= Displace and remove the console finisher veneer panel.
Cut and remove the rotary switch harness securing straps.
= Disconnect the rotary switch harness multi-pin plugs.
. Reposition the tunnel carpet for access to the harness
Displace and reposition the grommet down through the
. Feed the harness through the tunnel to the underside of
. Raise the vehicle on a ramp.
. From beneath the vehicle, release and remove the rotary
switch harness to transmission
'F" clip securing nut; dis-
place and reposition the 'P' clip from the stud.
Release and remove the rotary switch harness to trans-
mission 'P' clip securing screw.
Release and remove the rotary switch protection cover
(1 Fig.1) securing bolts; displace and remove the switch
cover.
shift
lever to
'N'.
n ect o rs .
@
grommet.
tunnel.
the vehicle.
Disconnect the transmission multi-pin socket (2 Fig.1).
. Reposition the harness clear of the transmission unit.
. Release and remove the rotary switch securing nuts.
. Displace and remove the switch assembly.
. Displace and remove the 'P' clips from the harness.
. Fit and align the 'P' clips to the new harness / switch as-
. Displace the rubber sealing plug (3 Fig.1) from the rotary
sembly.
switch.
i3 2 JLL-690
Fig.
1
X300 VSM 9 Issue 1 August 1994