1994 JAGUAR XJ6 brake

Automatic Transmission (V12 & AJl6 Supercharged) Pomrtrain
8.2.1 GENERAL DESCRIPTION
This section provides information relating to the Powertrain 4L80-E transmissions fitted to the 4,O liter supercharged
engine (4,OL SC) and to the 6,O liter engine (6,OL).
The Powertrain 4L80-E is a four-speed, high torque capacity, electronically controlled automatic transmission, which
comprises a torque converter with lock-up direct drive clutch and three planetary gear sets. Five multiple diskclutches,
one intermediate sprag clutch assembly, two roller clutch assemblies and two band assemblies provide the drive el- ements necessary for correct sequential gear engagement and operation.
The torque converter containing
a pump, a turbine (rotor), a stator assembly, and a clutch pressure disksplined to the
turbine, acts as a fluid coupling for smooth torque transmission from the engine. The converter also supplies addi- tional torque multiplication when necessary, and the torque converter clutch (TCC) pressure disk provides a mechan- ical direct drive or 'lock-up' above a certain speed in top gear for greater fuel economy.
Gearshift operations are controlled from the Transmission Control Module (TCM), which governs the electronically
controlled valve body situated within the transmission.
Three planetary gear sets provide reverse and the four forward ratios, the changing of which is fully automatic in rela
- tion to load, vehicle speed and throttle opening. The Transmission Control Module receives and integrates various ve- hicle sensor input signals, and transmits operating signals to the solenoids located in the control valve assembly.
These solenoids govern the transmission operating pressures, up-shift and down-shift gear selection patterns and
also the torque converter clutch operation by pulse width modulated control.
8.2.1.1 Gear Ranges
Selectable gear positions are: P - Park, R - Reverse, N - Neutral, D - Drive, 3, 2.
P - Park position of the shift lever provides a mechanical locking of the output shaft of the transmission, and as such,
must only be engaged when the the vehicle is stationary. In addition, and for
extra safety, the handbrake should also
be applied. It is necessary to have the ignition ON and the footbrake applied to move the shift lever from the Park
position. For ignition key removal the shift lever must be in the Park position. The engine can be started in the Park
position.
R - Reverse enables the vehicle to be operated in a rearwards direction. The engine cannot be started in the Reverse
position.
N
-Neutral position enables the engine to be started and operated without driving the vehicle. It also allows the vehicle
to be moved manually for access, ie for removal of the propeller shaft.
D
-Drive position allows the automatic selection of all four forward gear ratios during normal driving conditions for
maximum efficiency and fuel economy. On acceleration, down-shifts are obtained by depressing the accelerator pedal
or by manual selection. The engine cannot be started in this position.
3
- Manual third position allows automatic operation of the three lower gear ratios but inhibits selection of the fourth
ratio. This position is used for towing a trailer or negotiating hilly terrain when greater engine braking control is re- quired. The engine cannot be started in this position.
2 - Manual second position allows automatic operation of the two lower gear ratios but inhibits selection of the third
and fourth ratios. This position is used for heavy traffic congestion or negotiating hilly terrain when even greater en
- gine braking control is required than is provided by manual third. This ratio may be selected at any vehicle speed - even if the transmission is in third or fourth ratio, the transmission will immediately down-shift to second gear pro- vided the vehicle speed is below 137 km / h (85 mile / h). The engine cannot be started in this position.
N.g!b: With the Performance Mode switch in the NORMAL position, the vehicle will pull away in second gear. How- ever, if more than 75 per cent of throttle is applied when the vehicle speed is between zero and 13 km/ h (8 mile / h), then first gear will be selected. From 13 to 61 km/ h (8 to 38 mile/ h) first gear is obtainable by 'kick-down'.
In 'sport' mode thevehicle pulls away in first gear and the transmission operatesfully in all four forward gears.
X300 VSM 1 Issue 1 August 1994

Automatic Transmission (V12 & AJ16 Supercharged) Powertrain
0
8.2.13 LUBRICATION SYSTEM, DRAIN AND REFILL
(4,OL SC AND 6,OL)
SRO 44.24.02
. Raise the vehicle on a ramp.
. Position a drain tin below the transmission unit.
. Release and remove the fluid pan drain plug.
. Allow the fluid to drain.
Clean the drain plug, including the magnet and the fluid
pan drain plug face.
. Fit and tighten the fluid pan drain plug.
. Remove the drain tin from below the transmission unit.
. Lower the vehicle on the ramp.
Open the hood and fit
a suitable fender cover.
Remove and wipe the dipstick.
. Fit a funnel to the dipstick tube.
. Initially fill the transmission with 4,5 liters of fluid.
. Remove the funnel.
. Open the front door.
. Check that the parking brake is applied.
. Start the engine.
Apply the footbrake.
Run the shift lever through all positions, finally returning
to the Park position.
. Release the footbrake.
. Insert the dipstick, then remove and inspect the level.
. Fit the funnel to the dipstick tube.
. Fill the transmission to the 'COLD' level mark on the dip-
stick with the correct fluid, see the Powertrain Automatic
Transmissions Service Manual, General Data.
CAUTION: On no account should the vehicle be driven un- less the fluid level is at the 'COLD' level and the
system primed.
0
Remove the funnel.
. Replace the dipstick.
. Switch the ignition OFF.
. Remove the fender cover and close the hood.
= Close the door.
J&&Q: 0 After road testing the vehicle, the fluid level on the
dipstick should be between the 'HOT' Min I Max
marks. Check the level with the transmission at nor-
mal operating temperature (90 to 100°C), with the
engine left running and the transmission in the Park
position.
m
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Issue 1 August 1994 14 X300 VSM ~
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Driveshafts & Final Drive
9.3
SRO 51.10.24
Disconnect vehicle battery ground lead.
. Support the vehicle at the rear.
OUTPUT SHAFT END FLOAT, CHECK
Mount a dial test indicator (DTI) to the differential housing with the probe resting on the output shaft flange (DTI probe must be parallel to the output shaft center line and NOT at an angle).
. Push the wheel 1 shaft assembly inwards and zero the DTI; pull outwards and note the reading.
. If the end float exceeds 0,15 mm; firstly verify the shim preload and if this is found to be correct, renew the output
shaft bearing. See 51.10.22. this section, for shim check and renew operations.
9.4
SRO 51.20.19
rn Disconnect vehicle battery ground lead.
See operation 51.10.22. this section, for process detail, less bearing 1 oil seal renew.
OUTPUT SHAFT HOUSING ‘0’ RING, RENEW
Prior to removal of shaft assembly check output shaft end float in accordance with operation 51.10.24.
9.5 OIL SEAL - PINION FLANGE, RENEW
SRO 51.20.01
. Disconnect vehicle battery ground lead.
. Support the vehicle at the rear.
. Disconnect main handbrake cable at compensator.
’Match mark‘ the FLEXIBLE COUPLING to the differential DRIVE FLANGE and remove fixings.
Remove fixings center bearing to crossmember and push drive shaft rear section forward to disengage from pinion
spigot.
CAUTION: Under no circumstances must the flexible coupling (or its fixings) be loosened or removed from the drive
shaft flange.
Support the drive shaft, do not allow it to hang.
9 ‘Match mark‘ the drive flange retaining nut to both the pinion and the drive flange (Fig. 1).
. Slacken the flange retaining nut approximately half a turn and retighten to the ‘match mark‘ noting the required force.
. Remove the retaining nut, washer and drive flange.
CAUTION: Use only special tools; 18G 1205 to restrict rotation and JD 156 to remove drive flange.
. Inspect the drive flange oil seal surface for damage corrosion or grooving and replace as necessary.
. Remove oil seal from differential case taking care not to damage the machined counterbore.
rn Clean seal counterbore.
. Using special tool JD 198 fit replacement oil seal to differential case ensuring that, seal is square, fully seated and
If the force does NOT exceed 135 Nm, the final drive unit MUST be replaced.
Do not use abrasive cloth, or paper, to remove imperfections from the seal surface.
the
lip spring is not dislodged.
Apply grease to drive flange seal diameter and refit the flange to the pinion in the original position.
U: Do not hammer the drive flange onto the pinion; pull down with the drive flange nut.
Tighten the drive flange nut to the original noted torque PLUS 10%.
* Check that the pinion spigot radial run-out is to specifica- tion.
Fitting and reassembly is the reversal of this procedure en
- suring that drive shaft fixings are renewed and that the
shaft is aligned in accordance with Sub-Section 9.2.
Correct the final drive oil level if required.
. Tighten all fixings to specification.
Fig. 1
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Issue 1 August 1994 4 X300 VSM

Driveshafts & Final Drive
9.8 FINAL DRWE UNIT RENEW
SRO 51.25.13
. Disconnect vehicle battery ground lead.
. Support the vehicle at the rear and remove the rear road
wheels.
Disconnect brake pad wear sensor multi-plug at RH hub
carrier and remove tie straps from wishbone. Release
ABS speed sensors at
RH and LH hub carriers and remove
tie straps from wishbones.
. Remove rear brake calipers, see Section 12, and support
at bump stop. Disconnect main handbrake cable at com- pensator, short cables at joining piece and remove com- pensator.
. Remove fixings, FLEXIBLE coupling to differential DRIVE FLANGE.
CAUTIW: Under no circumstances must the flexible
coupling (or itsfixings) be loosened or removed
from the drive shaft flange.
. Remove fixings center bearing to crossmember (1 Fig. 1) and push drive shaft rear section forward to disengage
from pinion spigot. Fig. 1
w: Take account of any shims located between the center bearing and the crossmember.
. Release fixings and remove, over axle exhaust pipe mounting from wide mounting bracket.
. Support the rear suspension assembly from below and remove fixings from RH and LH sides in the following order:
1. Shock absorber to body upper fixings.
2. Differential strut to body (1 Fig. 2).
3. 'A' frame bush (2 Fig. 2).
4. Lower mounting bracket assembly to body (3 Fig. 2).
. Carefully lower the unit clear of the vehicle and place in a safe working location.
. Release handbrake cable to wide mounting bracket clips.
. Disconnect RH and LH axle shafts from differential couplings, note camber shim and discard fixings.
. Remove wishbone pivot bolt, washers and remove wisbone / hub / axle shaft assembly RH and LH.
issue 1 August 1994 6 X300 VSM

Driveshafts & Final Drive
. Remove upper link assembly from differential and wide mounting bracket / 'A' frame.
. Release fixings, 'A' frame to differential, 'A' frame to wishbone tie and wide mounting bracket to 'A' frame.
. Remove wishbone tie assembly, rear mounting bracket and pendulum assembly.
. Release fixings differential nose to wide mounting bracket.
. Assembly and fitting is the reversal of this procedure, taking note of the following:
Drive shaft must be aligned in accordance with Sub
-Section 9.2.
Renew all self locking nuts.
Renew all bolts that were originally fitted with thread locking adhesive.
Replace all locking wire and split pins (cotter pins).
Tighten all fixings to the specified torque.
Correct the final drive oil level
if required.
Check and adjust rear wheel camber setting as required.
9.9 AXLE SHAFT ASSEMBLY, RENEW
SRO
47.10.01
Disconnect vehicle battery ground lead.
. Slacken appropriate axle shaft hub nut.
. Support the vehicle at the rear and remove rear road
. Remove brake caliper in accordance with 70.55.03. Sec-
wheel.
tion 12, but do not disconnect hydraulics.
Slacken hub carrier fulcrum and remove ABS sensor from
hub carrier.
. Remove axle shaft hub nut and collar.
. Remove fixings axle shaft to differential output shaft
flange, note camber shim.
. With service tools JD 1D/7 (Fig. 1) and JD ID (Fig. 21, push
shaft through hub.
. Remove axle shaft assembly.
CAUTION: Take care not to introduce debris into the hub
bearings, or damage seal.
. Prior to assembly, remove all traces of adhesive from hub
. Assembly and fitting is the reversal of this procedure
Adhesive should be applied to axle shaft splines over
a radial area of
30 to 50%.
Renew all bolts that were originally fitted with thread
locking adhesive.
Replace all locking wire and split pins (cotter pins).
Tighten all fixings to the specified torque.
Check and adjust rear wheel camber setting.
Verify operation of brakes.
Renew all self locking nuts.
splines.
taking
note of the following:
0
NQ&: The axle shaft nut is a self-locking item with a thread
insert and must NOT be reused.
Fig. 1
Fig.2
- Iss ue 1 August 1994
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7 X300 VSM

Driveshafts & Final Drive
9.10 REAR HUB BEARING, RENEW
SRO 64.15.14
9.11
SRO 64.15.15
REAR HUB OIL SEAL, RENEW
Removal
= Disconnect vehicle battery ground lead.
= Slacken appropriate axle shaft hub nut.
. Support the vehicle at the rear and remove rear road
m: To aid assembly, markthe position of the head of the
hub carrier fulcrum, relative to the wishbone slot.
. Disconnect handbrake cable inner and outer.
. Remove brake caliper in accordance with Section 12, but do not disconnect hydraulics.
. Slacken hub carrier fulcrum and remove ABS sensor from
hub carrier.
. Remove axle shaft hub nut (and discard), collar and hub
carrier fulcrum.
. Using service tools JD 1D/7 and JD ID (Fig. I), push shaft
through hub and pull the hub carrier assembly clear.
. Using Hub tool JD 132 - 1 (1 Fig. 2) and a suitable press,
align the hub assembly tothetool ensuring the hand brake
expander locates into the tool cut out.
. Locate button JD 132 - 2 and press the hub from the
carrier.
. Remove the outer bearing race and seal from either the hub or the carrier and place the ABS rotor to one side.
. Remove from the carrier; bearing spacer, adjustable
spacer, inner race and seal.
Renew Bearings /Sea/($
wheel.
. Using a suitable drift remove the inner and outer bearing
cups.
. Clean all components paying particular attention to the re- moval of all tracesof lockingcompoundfrom the hub AND
axle shaft splines.
. Using service tools JD 550 - 4 /2,4 / 1 and 18G 134, fit new
cups to the hub carrier ensuring that they are 'square'and
fully seated.
Fit the new outer bearing race to the hub.
&&Q:
. Assemble the hub and race to the carrier along with bear-
Do not fit seals or 'pack' bearing at this point.
ing spacer (noting orientation) and the largest available
adjustable spacer,
i.e. 3.47 mm.
. Fit the new inner bearing and ABS rotor to the hub. Fig.
1
Fig.
2
. Apply a compressive load to the hub / bearing assembly, using a press, vice or long bolt. Ensure that the force that
. Measure the hub end-float, using service tool JD 13B dial test indicator (DTI).
. Using the indicated endfloat dimension, select a suitable adjustable spacer to give the specified pre-load.
m:
. Remove the outer bearing from the hub.
. Lubricate the bearings as specified.
. Locate the outer bearing to the hub carrier assembly.
the axle shaft
fixing would normally provide is not exceeded.
See Service Data, (preliminary pages) for pre
-load specification and typical example.
Issue 1 August 1994 8 X300 VSM

10.5 OUTER
TRACK ROD BALL JOINT, RENEW
sRo . Disconnect 57.55.02 vehicle battery ground lead.
. Raise the front of the vehicle and remove the appropriate
road wheel
Slacken the track rod
locknut but do not wind away from
the ball joint (1 Fig. 1).
m: Leave the lock-nut in its original position to initially
locate the new ball joint.
. Remove the track rod ball joint nut (and discard) (2 Fig. 1)
at the steering arm (3 Fig. 1).
. Using service tool JD 100 (1 Fig. 2), release the taper and
remove the ball joint (2 Fig. 2).
Fit the new track rod ball joint up to the lock-nut and se- cure at the steering arm with a new nut; tighten to specifi- cation.
. Fitting is the reversal of this procedure noting that the sus- pension should be fully settled prior to tracking adjust-
ment.
0 10.6 FRONT HUB ASSEMBLY, RENEW
SRO 60.25.01
10.7
SRO 60.25.12
10.8 FRONT HUB BEARING, RENEW
SRO 60.25.16
10.9
SRO 60.25.17
Disassemble
Disconnect vehicle battery ground lead.
. Support the vehicle at the front and remove the appropri-
. Remove brake caliper and disc assemblies see SRO 70 10
IWQ: Do not allow thecaliperto hang by either harness or
flexible hose.
FRONT HUB BEARING END FLOAT, CHECK
AND ADJUST
FRONT HUB
OIL SEAL, RENEW
ate road wheel (s)
10, section 12 for removal method only.
WARNIM: DO NOT INHALE BRAKE PAD DUST, ITMAY DAM-
0
AGE YOUR HEALTH.
. Prise of the hub grease cap (1 Fig. 3).
Remove and discard cotter pin (2 Fig. 3), pull off castel- lated nut retainer (3 Fig. 3).
Remove the hub nut and bearing washer.
Carefully remove the hub assembly (4 Fig. 3)fromthestub axle.
Hub oil seal. Prise the original seal from the spigot and dis-
card.
. Remove all traces of grease and dirt from the stub axle and
back plate.
. Lightly lubricate the stub spigot (to ease assembly of the
seal) and assemble the seal tothe spigot using special tool JD 179 (Fig. 4).
JS7-i 58 Fig. 1
Fig. 3
Fia.
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X300 VSM 9 Issue 1 August 1994

Suspension Systems
11.4.3 Front End Inspection
Do not check and adjust front wheel alignment without carrying out the following inspection for front end damage and
wear:
. Check for specified air pressure in all four tires.
Raise front of vehicle off the floor; grasping upper and lower surface of the tire, shake each front wheel to check for
. Check front suspension lower arm ball joint and mounts for looseness, wear and damage.
Check steering gear mountings and all steering linkages for looseness.
. Renew parts if necessary.
. Grasp upper and lower surface of tire and shake each wheel to check wheel bearing end play.
. Check the action of the front dampers and the condition of their attachments, as sticking or binding front dampers
worn
bearings.
Check brake caliper mountings.
may not allow the vehicle to settle in to a normal level position, possibly affecting the front-wheel alignment.
m: Front wheel bearings are adjustable (0.001 to 0.003 in. endfloat).
11.4.4
. Check the wheel bearings.
. Inspect the front suspension upper joint and renew front suspension lower wishbone if needed.
Raise vehicle and position floor jacks beneath the front suspension lower wishbone.
Grasp the lower edge of the tire and move the wheel in and out.
While moving the wheel, observe the upper and lower wishbone.
. Movement between the vertical links and the wishbones indicates abnormal ball joint wear.
. Renew ball joints.
. Check the front wheel bearings.
. Check for excessive play and wear.
Upper / Lower Ball Joint Inspection
11.4.5 Damper Inspection
m: The gas-pressurized hydraulic front dampers are not serviceable, adjustable or refillable.
Verify that all attachments of the suspension components and the front dampers are tight. Renew any front damper
. Check front dampers for external damage.
. Check for oil leakage and vehicle sag.
that
has a damaged integral lower mounting bushing.
0 Oil Leak
Leakage is the condition in which the entire damper body is covered with oil and from where
it will drip on to
the pavement. Due to correct damper lubrication a light film of oil (weepage) can usually be seen on the upper
portion of the damper.
Should there be any leakage, ensure that the fluid does not originate from sources other than the front damper.
Renew worn or damaged dampers.
0 Vehicle Sag
Renewing front dampers will not correct the problem of vehicle sag, as basically this is controlled by the spring
units.
issue 1 August 1994 4 X300 VSM