1994 JAGUAR XJ6 transmission

Manual Transmission & Clutch (AJ16)
. Remove front clamp from unit lift.
. Raise / lower unit with jack, no stands.
. Traverse lift under ramp and take weight of transmission.
. Adjust jacking platform angles to suit transmission.
. Adjust side and rear clamps to suit transmission and tighten clamp wing nuts.
. Fit the safety chain assembly to left hand arm of lift, and secure with peg.
Pass safety chain over transmission and engage in front arm of lift. Tighten the safety chain adjuster.
. Remove remaining transmission to adaptor plate securing bolts and carefully lower transmission from engine.
. Remove transmission from ramp area.
. Remove clutch release bearing assembly from release lever.
. Remove clutch release lever retaining clip and remove lever.
. Remove release lever pivot pin.
Remove transmission switch.
. Remove rear mounting spring retainer securing nut.
. Reposition selector shaft pin cover.
0
Remove rear mounting spring retainer and remove rear mounting assembly.
Remove selector shaft yoke to selector shaft retaining pin and remove the yoke.
. Remove slave cylinder securing studs.
. Remove the transmission from the unit lift.
. Remove transmission drain plug and allow to drain, refit
the drain plug.
Fit new transmission to unit lift.
Fill transmission with oil and refit the level plug.
. Clean components and mating faces.
. Fit the slave cylinder mounting studs.
. Lubricate the selector output shaft.
. Fit selector shaft yoke (3 Fig. 1) to selector shaft and secure
with retaining pin (2 Fig. 1).
Reposition the retaining cover (1 Fig. 1) over the selector
shaft yoke retaining pin. -
. Fit the transmission rear mounting assembly and secure
with bolt.
. Fit reverse lamp switch.
. Lubricate the clutch release lever.
. Fit and align lever to transmission and engage onto pivot
pin.
Fit and fully seat lever to pivot retaining clip.
= Lubricate release bearing housing.
9 Fit and fully seat bearing assembly to lever.
. Select third gear.
. Move transmission to vehicle and raise into position.
Fia. 1
. Insert transmission input shaft into clutch and fully seat transmission against adaptor plate, ensuring that trans- mission is in line as it is fitted and seated to the plate.
X300 VSM 3 Issue 1 August 1994

Manual Transmission & clutch (AJ16)
Fit and tighten transmission to adaptor plate securing
. Slacken chain adjuster.
. Release securing peg from adjuster.
. Displace securing chain from the unit lift.
. Slacken clamp from wing nuts.
. Release clamps from transmission.
. Lower lift and traverse aside.
Refit front clamp to unit lift.
. Connect transmission switch and fit multi-way connector
. Clean and lubricate clutch slave cylinder push rod and fit
. Fit slave cylinder to mounting studs and secure with nuts.
Fit and seat remote control mounting rubbers and
. Align remote control assembly to transmission.
. Fit mounting rubber backing washers.
Refit remote control mounting and secure with bolts (1
. Fit wavy washer to gearshift lever.
. Position selector shaft yoke to gearshift lever.
. Apply lubricant to selector shaft yoke / gearshift lever
. Fit and tighten selector shaft yoke to gearshift lever secur-
. From above: Tighten MS 538 hook nut to raise trans-
. Position the jack beneath the transmission.
bolts
(1 Fig. 1).
into
securing clip.
to slave cylinder.
spacers.
Fig.
2).
assembly.
ing nut
/ bolt (3 Fig. 2).
mission into position (Fig. 3).
. Fit spring to rear mounting assembly.
. Fit upper rubber to mounting spring.
Using a jack, fit and seat the mounting assembly to the body / transmission.
. Fit but do not fully tighten mounting securing bolts.
. Lower and remove jack.
. Remove jack channel.
. From above: Fully undo MS 53B hook nut.
. From below: Final align mounting to transmission / body.
. Final tighten the mounting assembly securing bolts.
. Clamp the front exhaust pipe in a vice.
. Remove and discard the front pipe to manifold sealing
. Clean the faces.
Fit and fully seat new rings to pipe.
. Remove the front pipe from the vice and align to the
. Align retaining rings to the studs and secure with the nuts.
rings.
man
ifold.
Fin. 1
Fig.
2
Fig. 3
Issue 1 August 1994 4 X300 VSM

Manual Transmission & Clutch (AJ16)
7.1.4 REAR OIL SEAL, RENEW
SRO 37.23.01
Remove the drive (propeller) shaft, see Section 9, SRO
47.15.01.
. Using a suitable oil seal remover, displace and removethe
rear oil seal (1 Fig. 1).
. Clean the seal mounting face.
. Lubricate the seal lip.
. Fit and seat the seal to the transmission.
. Refit the drive shaft, see 47.15.01.
7.1.5 GEARSHIFT LEVER, RENEW
SRO 37.16.04
. Remove and strip down the gear selector remote control
assembly as detailed in Sub-section 7.1.8.
. Rebuild and refit the gear selector remote control assem- bly (Sub-section 7.1.81, but fit a new replacement gear- shift lever and discard the original lever.
7.1.6 GEARSHIFTLEVER DRAUGHT EXCLUDER,
SRO 37.16.05 RENEW
. Remove
the gearshift lever knob (1 Fig. 2), see Sub-Sec-
. Open the centre console storage compartment.
tion 7.1.7.
= Remove the centre console securing screws, disconnect
Remove the foam sealing ring.
. Remove the draught excluder securing screws (2 Fig. 2)
and ring (3 Fig. 2) and remove the draught excluder (4 Fig.
2).
. Fit the new draught excluder over the gearshift lever and
secure with the ring (3 Fig. 2) and screws (2-Fig. 2).
. Refit the foam sealing ring.
Refit the centre console and reconnect the block
Close the centre console storage compartment.
. Fit the gearshift lever knob/ lock nut and align the knob to
Tighten the lock nut and reposition the gearshift lever
the
block connectors and remove the console.
connectors and secure with the screws.
its final position.
gaiter.
I --0-. I
J37.02~
Fin. 1
Fig. 2
0
0
0
Issue 1 August 1994 6 X300 VSM

Manual Transmission & Clutch (AJ16)
GEARSHIFT LEVER KNOB, RENEW
:RY 37.16.11
. Displace the gearshift lever gaiter for access and slacken
the gearshift lever knob lock nut (1 Fig. 1) and remove the
gearshift lever knob
(2 Fig. 1).
- Fit the new gearshift lever knob and align to its final posi- tion.
. Tighten the lock nut and reposition the gearshift lever
gaiter.
7.1.8 GEARSHIFT LEVER/ REMOTE CONTROL
ASSEMBLY, RENEW
SRO 37.16.20
. Disconnect the battery.
. Remove inlet manifold rear securing nuts.
. Fit lifting bracket 18G 1465 and secure with the nuts.
. Fit Service Tool MS 538 (Fig. 2) across the wing channels
and align to rear lifting bracket.
Fit and engage retaining hook.
. Tighten hook nut to take weight of engine.
Select third gear and remove the gearshift lever knob.
. Disconnect lambda sensor block connectors.
Remove the exhaust front pipe to the intermediate pipe
securing nut / bolt.
. Remove the sealing olive.
. Take the weight of the rear engine mounting using a jack,
. Remove the rear mounting securing bolts.
. Lower and remove the rear mounting assembly.
Carefully ease exhaust system down for access.
jack channel
and a suitable block.
. Remove the drive (propeller) shaft assembly, see Section 9, SRO 47.15.01.
. From above: undo retaining hook nut to lower rear of
transmission (do not allow engine to foul steering rack).
From below: slacken but do not remove the selector shaft
bolt
(3 Fig. 3).
. Remove the gear selector remote control securing bolts (1 Fig. 1) and reposition for access.
Finally remove the selector shaft bolt (3 Fig. 3).
. Remove the gear selector remote control assembly from
the selector shaft.
b: To aid removal, invert the gear selector remote con- trol assembly, i.e. gearshift lever pointing down- wards.
2
Fig. 1
Fig. 2
Fig. 3
X300 VSM 7 Issue 1 August 1994

Manual Transmission & clutch (AJ16)
. Ensure that the draught excluder is not displaced from its
. Remove the mounting rubbers and washers (2 Fig. 1).
. Mount the gear selector remote control assembly (1 Fig.
. Remove the spring ring (2 Fig. 2).
. Remove the gearshift lever (5 Fig. 2).
. Remove the spring retainer (3 Fig. 2) and spring (4 Fig. 2)
. Remove the gearshift lever lower nylon cup (6 Fig. 2) and
. Remove the lever housing assembly from the vice.
. Clean all components thoroughly and examine for wear
. Replace worn or damaged components as necessary.
. Ensure mating faces are clean and grease-free.
. Mount the gear selector remote control assembly (1 Fig.
. Fit and seat the lower nylon cup (6 Fig. 2).
. Grease the gearshift lever ball.
Fit and seat the upper nylon cup (7 Fig. 2).
. Fit the spring (4 Fig. 2) and spring retainer (3 Fig. 2) to the
. Fit and seat the gearshift lever
. Compress the spring (4 Fig. 2).
* Fit and seat the spring ring (2 Fig. 2).
= Remove the gear selector remote control assembly (1 Fig.
Lubricate the gearshift lever to ease fitment through the
Lubricate the lower spacer.
Position the assembly in its mounting location; enter the
. Position the gearshift lever into the selector shaft yoke.
. Fit but do not tighten the selector shaft bolt (3 Fig. 1).
Fit the lower LH mounting rubber and washer.
. Fit the remaining mounting rubbers / washers (2 Fig. 1)
Secure the selector shaft bolt (3 Fig. 1).
. Tighten MS 538 hook nut to raise the transmission into
position.
. Using a jack, fit and seat the rear mounting to the trans- mission / body, ensuring that the spring is seated correctly
in the spring pan.
position.
2) in
a vice.
from the gearshift lever.
upper nylon cup (7
Fig. 2).
and damage.
2) in a vice.
lever.
2) from the vice.
draught excluder.
gearshift lever into the gaiter.
and secure with the bolts
(1 Fig. 1).
. Fit but do not fully tighten the mounting securing bolts.
. Remove the jack and jack channel.
Secure the rear mounting bolts.
. Slacken off MS 538 hook nut.
. Refit the drive (propeller) shaft assembly, see Section 9, SRO 47.15.01.
Remove Service Tool MS 538.
. Refit the gearshift lever knob.
Fin. 1
J37-WB
Fig. 2
Issue 1 August 1994 8 X300 VSM

Manual Transmission & Clutch (AJ16)
GEAR SELECTOR SHAFT- REAR, OVERHAUL
iRY 37.16.41
. Remove the gear selector remote control assembly, see
Displace the selector shaft cover (1 Fig. 1).
. Remove the selector shaft to selector shaft yoke retaining
. Clean all components thoroughly and check for wear and
. Replace worn or damaged components as necessary.
Lubricate and fit the selector shaft yoke to the selector
. Reposition the selector shaft cover.
. Refit the gear selector remote control assembly, see
37.16.20.
pin
(2 Fig. I), and remove the yoke (3 Fig. 1).
damage.
shaft and secure with the retaining pin.
37.16.20.
7.1.10 REVERSE LAMP SWITCH, RENEW
SRO 37.27.01
. Raise the vehicle on a ramp.
. Note and disconnect reverse lamp switch multi-way
= Slacken off and remove the switch.
Clean the mating face.
Fit a new switch.
. Connect the multi-way connector.
. Lower the ramp.
connector.
7.1.11 LAYSHAFT FRONT SEAL, RENEW
SRO 37.23.07
a Remove the transmission assembly, see Sub-Section
. Removethefront oilseal assembly,seeSub-Section7.1.3.
. Using suitable oil seal remover tool, remove and discard
. Clean the transmission face and the front oil seal assem-
. Fit and fully seat the new seal to the casing.
= Refit the transmission front seal assembly.
. Refit the transmission.
7.1.2
layshaft plug
seal.
bly. Fig.
1
X300 VSM Issue 1 August 1994 9

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 (AJl6)
0
7.1.13 CLUTCH FAULT DIAGNOSIS
symptom
lifficult gear ?ngagement
3attling clutch
squeaking clutch
dibrating clutch or
:lutch judder (often pre- :eded by clutch grab)
stiff clutch operation
Possible Cause
Hydraulic system
defects
Operating mechan
- ism faults
Clutch unit faults
Primary pinion bear
-
ing fault
Clutch unit faults
Defects other than in
clutch unit
Operating linkage
fault
Check
Check fluid level in reservoir
Check for air in the system
Check for defective pedal
Check for damaged pressure plate
Check splines on clutch driven
plate and primary pinion shaft for
wear
Check clutch driven plate for loose
or broken springs and for warping
Check for wear in the clutch with
- drawal mechanism
Check for worn primary pinion
bearing
Check for seizing on primary shaft
or in flywheel
Check the clutch driven plate for
distortion and damage and for
loose or broken torque damper
springs
Check for oil and other foreign
matter on the clutch friction linings
Check for incorrectly fitted clutch
pressure
plate
Check that contact witness on fric-
tion linings is evenlv distributed -
Check for loose flvwheel fixings
and flywheel
run-out
Check for loose engine mountings
Check for worn drive (propeller)
shaft universal joints
Check for bent primary pinion
shaft
-
Check for damaged moving parts
in operating linkage
- -
Check for seized linkage, recheck
operation after remedv
Remedy
Replenish as necessary and
bleed system if necessary
Bleed the system
Renew return spring if
necessary
Renew pressure plate
Renew as necessary clutch
plate or primary pinion
Renew driven plate
Renew as necessary
Renew as necessary
Lubricate or renew as
necessary
Renew driven plate
Renew driven plate and clean
related parts
Dismantle from clutch and
refit where applicable
Renew driven plate as
necessary
Tighten to correct torque
loading
Lubricate linkage as
necess-
X300 VSM 11 Issue 1 August 1994