1994 JAGUAR XJ6 clutch

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)
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

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
1.
2.
3.
4.
5. 6.
7.
8.
9. 10.
11.
12.
13.
Torque converter
Turbine shaft
Pressure disk
Converter turbine
Converter stator
Variable force motor
solenoid
Fluid pan
Filter
Interior detent lever
Manual shaft
Control valve
Front band
Parking lock actuator
3 4667 i JU-134
14.
15.
16.
17.
18.
19.
20. 21.
22.
23.
24. 25.
Rear band
Sun gear shaft
Sun gear
Parking lock pawl
Transmission case
Output shaft
Rear extension housing
Rear internal gear
Output planetary carrier
assembly Reaction planetary
carrier assembly
'LO' roller clutch
Main shaft
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
Intermediate clutch Intermediate sprag clutch
Direct clutch
Forward clutch
Overdrive planetary carrier
assembly
Overdrive roller clutch
Overrun clutch
Fourth clutch
Pump assembly
Converter pump
Stator roller clutch
Output speed sensor
Fig.1 Powertrain 4L8O-E automatic transmission
0
0
0
Issue 1 August 1994 2 X300 VSM

Powertrain Automatic Transmission (V12 & AJ16 Supercharged)
Light throttle D1 -D2 D2 - D3 D3 - D4
Normal mile 1 h 8- 10 18-20 25 - 39
kmlh 13- 15 28 - 33 40 - 46
sport mile 1 h 10 - 12 20 - 23 30 - 34
kmlh 16- 19 32 - 37 48-55
Up to Detent D1- D2 D2 - D3
Normal mile I h 34 - 37 60-66
kmlh 54 - 59 97 - 107
8.2.1.2 Shift Speeds
0
D4 - TCC on
45 - 51
72
-83
47
- 55
76
-88
D3
- D4
86
-94
138
- 151
4,O Liter Supercharged
sport mile I h 43 - 47 74 - 81 103 - 113
kmlh 69 - 76
118- 130
166 - 182
Maximum shift speeds (through detent)
Normal 1 Sport mile I h
kmlh
D1 -D2 D2 - D3 D3 - TCC on
47 - 50 81 -84
116 - 128
75
- 80 130 - 134
187 - 205
TCC
-Torque converter clutch
m: Road speeds shown above are for a vehicle with an axle ratio of 3,58:1, and standard tyres (2251 65ZR15). For
a vehicle with optional sports tyres
(225 / 55ZR16) (lattice wheels), these speeds must be reduced by 2,4%.
Zero throttle 1 TCCoffinD4 1 D4 - D3 D3 - D2
X300 VSM 3 Issue 1 August 1994
D2 - D1
Normal mile 1 h
kmth
sport mile 1 h
kmlh
I 36 - 40 15- 17
10- 12 -
58-64 24 - 27 16- 19 -
36 - 40 18 - 20 12 - 14
9-9
58-64 29 - 32 20 - 22 14 - 15
Up to
detent D4 - D3 03 - D2
Normal mile 1 h 67-74 3-44
kmlh 107-118 63-70
sport mile 1 h 81 -89 57 - 63
kmlh 130- 144 92 - 101
Kick-down available (through detent) TCC4 - D3 D3 - 02
Normal 1 Sport mile I h 103- 113 67 -74
kmlh 165 - 183 107 - 118 D2
- D1
9-9
14
- 15
27
- 29
43 - 47
D2
- D1
36 - 40
58-64

Automatic Transmission (V12 & AJ16 Supercharged)
Light throttle D1 -D2
Normal mile 1 h -
km/h -
sport mile / h 10- 12
kmlh 16- 18
Up to detent
Normal mile I h
kmlh
sport mile
1 h
km/h
Maximum shift speeds (through detent)
Normal I Sport mile / h
kmlh
6,O Liier
D2 - D3
D3 - D4
D4 - TCC on
20 - 23 29 - 33
48 - 55
32
- 37 46 - 52
77 -88
23 - 26 32 - 37 51 -59
36
- 41 51 -59 82 - 94
D1 -D2
D2 - D3 D3 - D4
35
- 40 61 -70 83-91
56
- 64 98- 112 133 - 164
43 - 49 73 - 79 99 -107
68
-78 117 - 127 158 - 172
D1 -D2 D2 - D3
D3 - TCC on
48-53 81 -89
116- 124
77
- 85 130- 149
186 - 198
Zero throttle
Normal mile 1 h
kmlh
sport mile
1 h
km/h
TCC off in 04 D4 - D3 D3 - D2 D2 - D1
- 36 - 40 15 - 17 10 - 12
16
- 19 58 - 64 24 - 27
36
- 40 18 - 20 12-14 6-7
58
- 64 29 - 32 19 - 22 10- 12
-
0
0
Up to detent
Normal mile I h
kmlh
sport mile
/ h
km/h
mile I h
kmlh
'Kick-down' available (through detent)
Normal 1 Sport
TCC -Torque converter clutch
m: Road speeds shown above are for a vehicle with an axle ratio of 3,58:1, and standard tyres (2251 65ZR15). For
a vehicle with optional sports tyres
(225 155ZR16) (lattice wheels), these speeds must be reduced by 2,4%.
D4 - D3 D3 - D2 D2 - D1
67 - 75 37 - 41 7-9
108
- 119 59 - 66 11 - 14
84
-92 60 - 66
27 - 29
134
- 148 96 - 106
43 - 47
TCC4
- D3 03 - D2 D2 - D1
103 - 113 67 -75 36 - 40
164
- 181 108 - 119 58 - 64
0
0
Issue 1 August 1994 4 X300 VSM