1994 JAGUAR XJ6 torque

Manual Transmission & Clutch (AJ16)
'ossible Cause
:Iutch Fault
'rimary pinion bear-
ng
ncorrect fitting nethod
Clutch Fault Diagnosis
Check
Check for worn clutch driven plate
hub splines
Check for wear in bearing
Damage may be caused by
acci- dental loading during fitting
Symptom
:I utch knocks
herloading vehicle
hiving with
left foot
,esting on clutch )edal
:ractured clutch )late
Check mating components for
damage
Refer to owners handbook for per
-
missible load details
Check as described under 'slipping
clutch'
Excessive
lining wear
lperating mechan-
sm faulty
:Iutch unit faults
3rabbing clutch
harsh engagement
'rom standing start,
Iften followed by clutch
udder) Check
operating mechanism for
wear and binding which usually
indicates
a binding withdrawal
race thrust bearing
Check pedal for sticking parts in
-
cluding return spring
Check for oil on friction driven
plate
Checkclutch plate and flywheel for
wear. Check flywheel
runout. Check also for glazing on driven
plate linings
Check for driven plate hub splines
sticking on pinion shaft.
Check pinion shaft for wear.
Check for broken or weak pressure
springs.
Check torque damper springs in
clutch driven
plate
hgine mounting Check
for damaged or deteriorated
engine mountings.
Check fixings for tightness
Remedy
Renew driven plate
Renew as necessary
Always support trans
- mission weight during fitting
Renew driven plate
Fit replacement clutch as-
sembly
Fit replacement clutch as- sembly
Free
off bearing. Renew as
necessary
Free
off pedal and check for
damaged and distorted
parts.
Renew
if necessary
Clean
off cover.
Renew faces.
Rectify oil
leak
Reclaim or renew as appli-
cable
Free driven plate, and check
for wear and distortion
Renew
if necessary
Renew
if necessary
Issue 1 August 1994 12 X300 VSM

1. SERVICE TOOLS & fQUlPMENT
Illustration
::(())(((((
Jaguar Number
JD 103
JD 161
Description Notes
Throttle valve alignment tool
Rotary switch setting tool
11. TORQUE TIGHTENING SPECIFICATIONS
Fixing Tightening Torque
(Nm)
Dipstick tube union nut 90
Drain plug 15
Fluid filter screws 8
Fluid pan securing bolts 8
Rotary switch to mounting bracket nuts
Transmission oil cooler pipes
20
10- 12
15- 18 Switch guard to sump pan bolts
111. SERVICE MA TERlA L S
Description USeS Notes
To be issued

Automatic Transmission (AJ16)
8.1.1 GENERAL DESCRIPTION
’ This section provides information relating to the automatic transmissionsfitted to the 3,2 liter engine (ZF 4 HP 22 trans- mission) and the 4,O liter normally aspirated engine (ZF 4 HP 24 E transmission). The general arrangement of the two
units is shown in Fig. 1 and Fig. 2. The two automatic transmission units differ in the type of control unit employed:
the purely hydraulic control used in the ZF 4 HP 22 unit shifts gears automatically at predetermined points, while the
electronic-hydrauliccontrol oftheZF 4 HP 24 E unit providesforoptimized shift point sand shift quality based on engine
and transmission data received by the Transmission Control Module (TCM).
P \R J44-607
1. Torque converter 8. Shift lever positions:
2. Throttle cable
‘P - Park
3. 4
-speed gear train ‘R‘ - Reverse
4. Output flange ‘N’ - Neutral
5. Transmission control unit
6. Oil outlet (drain plug) 9. Dipstick/ oil filler tube
7. Shift cable attachment 10. Oil cooler connection
‘D‘
- Drive - Fully automatic
control
Fig. 1 ZF 4 HP 22 Transmission
X300 VSM 1 Issue 1 August 1994

I 1 I
8-
/ /
7, 6
'4 '5
J4L- 688
1. Torque converter 6. Rotary switch positions:
2. &speed gear train 'P - Park
3. Output flange 'R' - Reverse
4. Transmission control unit 'N' - Neutral
5. Oil outlet (drain plug) 'D' - Drive
(Fully automatic control)
7. Dipstick/ oil filler tube
8. Oil cooler connection
Fig.
2 ZF 4 HP 24 E Transmission
X300 VSM Issue 1 August 1994 2

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

Automatic Transmission (AJ16)
8.1.1.3 Shift Speeds
3,2 Liter
Up to 'kickdown point' D4 - D3 D3 - D2
D2 - D1 -
km/h 102 - 114 67 - 78
36 - 50 -
- mile / h 64-71 42 - 48 22 - 31
'Kick-down' available D4 - D3 D3 - D2 D2 - D1
mile I h 86-99 61 -67 30 - 37 -
kmlh 139 - 160 98- 108 48 - 60 -
available speed) -
km/h 108- 123 - -
- - Manual inhibit (maximum D4 - D3 D3 - D2
- - mile 1 h NOT INHIBITED 67 -76
TCC
- Torque converter clutch
Issue 1 August 1994 4 X300 VSM

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)
8.1.4 TRANSMISSION ROTARY SWITCH, ADjUST
SRO 44.15.37
. Raise the vehicle on a ramp.
. Position the shift lever to 'N' ensuring that the stalk enters
the gate
'N' notch centrally.
9 Release and remove the transmission unit rotary switch
protection cover
(1 Fig.1) to fluid pan bolts.
. Remove the rotary switch protection cover from the fluid
pan bosses.
. Slacken the rotary switch to mounting bracket securing
nuts.
Displace the rubber blanking plug from the rotary switch
center boss
(2 Fig.1).
. Fit Service Tool JD161 (Fig.2) to the rotary switch to align
the switch rotor with the switch body.
CAUTION: Service Tool JD161 is a precision tool and
. Evenly torque tighten the rotary switch to mounting
. Disengage and remove ServiceTool JD161 from the rotary
. Fully seat the rubber blanking plug into the rotary switch
. Fit the rotary switch protection cover and align with the
. Fit and torque tighten the rotary switch protection cover to
Lower the vehicle on the ramp.
. Check for correct operation of start inhibit and gear selec-
(4,011
should be treated as such.
bracket securing nuts.
switch.
center boss.
fluid pan bosses.
fluid pan securing bolts.
tion.
12 JL 4 - 689
Fig. 1
Fin. 2
X300 VSM Issue 1 August 1994 8