manual transmission JAGUAR XJ6 1994 2.G Owner's Guide
[x] Cancel search | Manufacturer: JAGUAR, Model Year: 1994, Model line: XJ6, Model: JAGUAR XJ6 1994 2.GPages: 521, PDF Size: 17.35 MB
Page 135 of 521

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
Page 140 of 521

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
Page 141 of 521

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
Page 143 of 521

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
Page 151 of 521

Automatic Transmission (AJ16)
8.1.11 TRANSMISSION INTERNAL HARNESSMULTI-
PIN SOCKET '0' RING, RENEW (4,OL)
SRO 44.24.20
. Disconnect the battery.
. Raise the vehicle on a ramp.
. Drain the transmission lubrication system, see Sub-sec-
. Remove the fluid pan, see Sub-section 8.1.7.
. Remove the fluid filter, see Sub-section 8.1.6.
. Remove the transmission speed sensor, see Sub-section
8.1.10.
. Disconnect the rotary switch harness multi-pin plug
(1 Fig. 1) from the transmission multi-pin socket.
. Release and remove the multi-pin socket to main trans-
mission casing securing nut.
. Release and remove the valve body assembly, ensuring
that the
multi-pin socket is freed from the main case aper-
ture.
. Remove the valve body harness multi-pin socket '0' ring
and discard.
. Clean the valve body and mating faces.
. Fit a new '0' ring to the multi-pin socket
. Fit thevalve body assembly to the transmission unit. Dur-
ing valve body fitment, engage the shift lever quadrant
peg into the manual valve and seat the
multi-pin socket
through the main case orifice.
m. Theflat onthesideofthe multi-pinsocket should be
located on the vertical (left-hand) side of the case.
. Fit but do not tighten the valve body assembly securing
screws.
. Gently push the valve body assembly forward to assume
this position
during the final tightening operation.
. Carry out final tightening of the valve body assembly to
main casing securing screws.
Fit and tighten the harness
multi-pin socket to main casing
securingnut.
. Connect the rotary switch harness multi-pin plug to the
transmission
multi-pin socket.
. Refit the speed sensor, see Sub-section 8.1.10.
Renew the fluid filter, see Sub-section 8.1.6.
. Refit the fluid pan, see Sub-section 8.1.7.
. Lower the vehicle on the ramp.
. Reconnect the battery.
. Refill the transmission unit with fluid, see Sub-section
8.1.2.
. Remove the fender cover and lower the hood.
Raise
the hood and
fit a fender cover.
tion
8.1.2.
Fig. 1
Issue 1 August 1994 14 X300 VSM
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Automatic Transmission (AJ16)
8.1.12 VALVE BODY ASSEMBLY, RENEW (4,Ol)
SRO 44.40.01
Raise the hood and fit a fender cover.
. Disconnect the battery.
. Raise the vehicle on a ramp.
. Drain the transmission lubrication system, see Sub-sec-
. Remove the fluid pan, see Subsection 8.1.7.
. Remove the fluid filter, see Sub-section 8.1.6.
. Remove the transmission speed sensor, see Subsection
8.1.10.
. Disconnect the rotary switch harness multi-pin plug from
the transmission multi
-pin socket.
. Release and remove the multi-pin socket to main trans-
mission casing securing nut.
Release and remove the valve body assembly to main cas-
ing securing screws.
. DisDlace and remove the valve body assemblv, ensurina
tion
8.1.2.
that
the multi-pin socket is freed from the main case apery
ture. - . Remove the valve body harness multi-pin socket '0' ring
. Clean the valve body and main case mating faces. Check
. Fit a new '0' ring to the multi-pin socket.
. Fit the valve body assembly to the transmission unit. Dur-
ing valve body fitment, engage the shift lever quadrant
peg into the manual valve and seat the multi
-pin socket
through the main case orifice.
m: Theflat on the side of the multi-pin socket should be
located on the vertical (left-hand) side of the case.
. Fit but do not tighten the valve body assembly securing
screws.
Gently push the valve body assembly forward to assume
this position during the final tightening operation.
Carry out final tightening of the valve body assembly to
main casing securing screws.
. Fit and tighten the harness multi-pin socket to main casing
. Connect the rotary switch harness multi-pin plug to the
. Refit the speed sensor, see Subsection 8.1.10.
. Renew the fluid filter, see Subsection 8.1.6.
Refit the fluid pan, see Sub-section 8.1.7.
* Lower the vehicle on the ramp.
. Reconnect the battery.
. Refill the transmission unit with fluid, see Sub-section
8.1.2.
. Remove the fender cover and lower the hood.
and discard.
for any signs of damage.
securing nut.
transmission multi
-pin socket.
Issue 1 August 1994 X300 VSM 15
Page 154 of 521

Ponnrtrain Automatic Transmission (V12 & AJ16 Supercharged)
SECTION CONTENTS
Sub-Section Title SRO Page
It0 IV ............ Preliminary Pages .................................................................... i
8.2.1 ............. General Description .................................................................. 1
8.2.2 ............. Transmission internal Harness. Renew (4. OL SC and 6. OL) ............ 44.15.35 ............. 5
8.2.3 ............. Pressure Switch Manifold. Renew (4. OL SC and 6. OL) ................ 44.15.39 ............. 6
8.2.4 ............. Input Speed Sensor, Renew (4. OL SC) .............................. 44.15.40 ............. 7
8.2.5 ............. OutputSpeedSensor, Renew(4. OL SC) ............................ 44.75.41 ............. 7
8.2.6 ............. input Speed Sensor, Renew (6. OL} ................................. 44.15.40 ............. 8
8.2.7
............. Output Speed Sensor, Renew (6. OL) ............................... 44.15.41 ............. 9
8.2.8.
............ Temperature Sensor, Renew (4. OL SC and 6. OL) .......................................... 10
8.2.9
............. Variable Force Motor, Renew(4. 0L SC and 6.OL) ..................... 44.15.43 ............ 70
8.2.10. ........... Pulse Width Modulator (TCC Solenoid). Renew (4. OL SC and 6. OL) ..... 44.15.44 ............ 11
8.2.17 ............ 'A' Shift Solenoid. Renew (4. OL SC and 6. OL) ....................... 44.15.45 ............ 12
8.2.12.
........... '6' Shift Solenoid. Renew (4. OL SC and 6. OL) ....................... 44.15.46 ............ 13
8.2.13
............ Lubrication System. Drain and Refill (4. OL SCand 6. OL) .............. 44.24.02 ............ 14
8.2.14
............ Fluid Pan. Renew (4. OL SC} ...................................... 44.24.04 ............ 15
8.2.15 ............ Fluid Pan. Renew (6. OL) ......................................... 44.24.04 ............ 16
8.2.16.
............ Fluid Pan Gasket. Renew (4. OL SC) ................................ 44.24.05 ............ 17
8.2.17. ........... Fluid Pan Gasket. Renew (6. OL) .................................. 44.24.05 ............ 78
8.2.18. ........... Fluid Filter, Renew (4. OL SC and 6. OL) ............................. 44.24.07 ............ 19
8.2.19 ............ Transmission Internal Harness Multi-pin Socket '0' Ring.
Renew (4.
OL SC and 6. OL) ....................................... 44.24.20 ............ 20
8.2.20
............ Internal Lubrication Pipe. Renew (4. OL SC and 6. OL) ................ 44.24.21 ............ 21
8.2.21
............ internal Dipstick Stop. Renew (4. OL SC and 6. OL) ................... 44.24.22 ............ 22
8.2.22.
........... Manual Detent Spring. Renew (4. OL SC and 6. OL) ................... 44.26.10 ............ 23
X300 VSM i Issue 1 August 1994
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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
Page 157 of 521

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
Page 169 of 521

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
0
Issue 1 August 1994 14 X300 VSM ~
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