differential JAGUAR XJ6 1994 2.G Workshop Manual

Introduction
Term(s) Abbreviation Definition
(if applicable) Previously
used term(s) (or Eng-
lish Equivalent)
downshift
draft _.
drivability
driveshaft
driveshaft tunnel
dry sleeve
Dual Overhead Cam
Data
Data Link Connector
Data Output Line
defogger, backlight defogger
degree (angle or temperature)
Department of Transportation
(US)
Department of Transport (UK)
Deutsche lnstitut fur
Normuna
diameter
Diagnostic Module
Diagnostic Test Mode
Diagnostic Trouble Code
differential housing
differentia
I pressure
Differential Pressure Feedback
EGR
dimmer switch DOHC
DLC
DOL
deg, O
DOT
DTP DIN dia
DM
DTM
DTC
DPFE longitudinal
shaft transmitting power from
transmission output to rear axle differential
tunnel
in floor above the driveshaft (propeller
shaft)
cylinder sleeve which is not in contact with
coolant
engine configuration with two camshafts
positioned above the valves
(US) Fact or group of facts.
connector providing access
andlor control of
the vehicle information, operating
conditions, and diagnostic information
circuit that sends certain information from
the PCM to the instrument cluster
German Standards regulation body
Supplemental Restraint System
(non-controlling) module for diagnostics
overview
a level of capability in an OBD system. May
include different functional states
to observe
signals, a base level to read
DTCs, a monitor
level which includes information on signal
levels,
bi-directional control with onloff board aids, and the ability to interface with
remote diagnosis
an
alphahumeric identifier for a fault
condition identified by the On
-Board
Diagnostic
(OBD) system
rotating housing
(in a bevel differential)
attached to the crownwheel, carrying the
final drive pinions
pressure difference between two regions e.g.
between intake manifold and atmospheric
pressures
an EGR system that monitors differential
EGR pressure across a remote orifice
to control EGR flow change
down
draught
driveability
propeller shaft
transmission
tunnel
dry liner
(English) Group
of facts (i.e. plural
of
datum)
HRW, rear screen
heater, demister
Self Test Mode
Self Test Code.
Fuel Fail code
differential cage
dip switch,
dipper switch
Issue 1 August 1994 11 X300 VSM

-5 Driveshafts & Final Drive
0
Fixing
11. TORQUE TIGHTENING SPECIFICATIONS
Tightening Torque
(Nm)
'A' frame to differential 85 - 115
'A' frame to wide mountina bracket 72 - 98
ABS sensor to hub carrier
Axle shaft hub nut
* See repair operations 47.10.01 and 64.15.14 & 15 this don
8- 10
304 - 336 *
Axle shaft to output flange
Bush,
'A' frame lower mounting to body
81 -99
80
- 100
Centre drive shaft bearing to crossmember 19 - 27
Crossmember to bodv 19 - 27
Differential nose to wide mounting bracket - 34 - 46
Issue 1 August 1994 iv X300 VSM
Differential strut to bodv 85 - 95
Drive shaft to auto-gearbox flange
Drive shaft flexible coupling to pinion flange 33 - 45
71
-83
Exhaust joint 'Olive'
Exhaust joint 'Torca clamp' -. 14-18
60
- 80
Exhaust mounting to wide mounting bracket
Final drive unit to wide mounting bracket at differential 'nose'
Hub carrier fulcrum 22-88
34
- 46
80
- 100 ___
Lower shock absorber bolt
Mounting bracket
('A' frame) to body (inner)
Mountina bracket
('A' frame) to bodv (outer)
- 80- 100
40 - 50
80 - 100
Oil drain plug __ 26 - 34
Oil filler DIU~ 20 - 26
Output shaft housing to differential case
Pendulum assembly to differential
Pinion drive flange nut
* See repair operation 5120.01 this section
Road wheel -Alloy
Road wheel - Steel
Upper link to differential
Rear
mounting bracket to differential
52 - 58
160
- 200
Minimum 135 *
85 - 105
88 - 102
68
-82
72
- 98 ~~~~~
Upper
link to wide mounting bracket & 'A' frame
Wide mounting bracket to
'A' frame
85-115
85
-115
Wishbone pivot nut
Wishbone tie to differential stud 80 - 100
85 - 105

Driveshafts & Final Drive
Description Use8
Loctite 270 Adhesive
Hylosil 102
-Sealant
Retinax A grease Axle shaft spline
Output shaft bearing housing to differential
case
Rear
hub bearings and seal pre-lubrication
Notes
30 / 50% radial coverage
See Sub Section
IV Service
I -
0
I -
minus 0.08 = 3.07 mrn (required adjustable spacer)
Minimum specified pre-load 0.025, therefore 3.15
minus 0.025 = 3.125 mm (required adjustable spacer).
Adjustable spacers are available
in 0,05 mm increments
from
2,22 to 3,47 mm.
I Data
IU SERVICE DATA
Rear hub bearing grease - Quantity
Final drive
unit pinion spigot radial run-out
0
0
Specification
0,025 to 0,08 mm
Inner bearing race1 1,5 ml. Outer bearing race 9,0 ml
Must not exceed 0,08 mm TIR (total indicator reading).
Should the run-out exceed the stated limit, renew the
final drive
unit.
X300 VSM V Issue 1 August 1994

Driveshafts & Final Drive
9.1 MAJOR COMPONENT DESCRIPTION
Power is transmitted from the gearbox to the final drive unit via a two piece drive shaft (formerly known as ‘propeller
shaft’) which is supported by a center bearing. Isolation from vibration and transmitted harshness is suppressed by
rubber mounting of both the center bearing and the connection of the drive shaft to differential drive flange.
The
hypoid final drive assembly is available with either a conventional, or a limited slip differential.
The limited slip, ‘Powr
-LoK unit may be identified by either a tag carrying the legend ’PC or a label with an ‘X, both
to be found on the rear cover.
U
Forged axle shafts (formerly known as ‘drive shaft’) transmit drive from the differential to the rear wheels, each shaft
having two universal joints. The axle shaft acts as an upper suspension link and controls static wheel camber by insertion of appropriate shims between the final drive unit and axle shaft inner flanges. Each axle shaft is supported
at the outer end by preloaded taper roller bearings housed in a cast aluminium hub carrier.

Driveshafts & Final Drive
9.2 DRIVE SHAm, ALIGN
SRO 47.15.51
CAUTION: To preserve 'drive line' refinement, individual parts, other than fixings, MUST NOT be renewed. In the
event of any balance or drive shaft component related problem, the complete assembly must be renewed.
Under no circumstances must the flexible coupling (or its fixings) be loosened or removed from the drive
shaft flange.
Preliminary Checks
Before this procedure is actioned it is advisable to ensure that:
The gearbox mounting center stud is positioned centrally in relation to the crossmember inspection hole.
The crossmember is central on the body fixings and not 'hard over' to one side.
The differential spigot radial
run-out is within specification, see preliminary pages.
If the vehicle has been standing for
a period the tires may be 'flat-spotted'. If so, this will clear in approximate.;
400 km (250 miles). After this distance the source of vibration should be reassessed.
12 Cylinder
8 Remove exhaust center section.
All
8 Locate suitable 'plumb lines' over drive shaft outside diameter, but NOT over any balance weight or weld:
1.
2.
3.
l\lnfe:
Front section -behind gearbox output coupling, 12,7 mm (0.5 in) diameter weight (1 Fig. 1).
Rear section - immediately behind center bearing (2 Fig. 1).
Rear section - in front of differential flange (3 Fig. 1)
It is essential that the front weight should be as specified so that the different diameters of the two shafts may
be taken into account.
Method 1
8 Viewed from the rear with the rear 'plumb line' coincidental with the outside diameter of the front weight, the center
8 To re-align the center bearing, slacken bearing fixings and position to suit.
8 Tighten all fixings to specification ensuring that the 'anti-twist' plate is allowed to freely align before the center bear-
'plumb line' should align with the rear 'plumb line' (4 Fig. 1).
ing fixings are secured.
Fig. 1
1
JL7 OL3
0
0
0
0 ~~~~
Issue 1 August 1994 2 X300 VSM

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
0
Issue 1 August 1994 4 X300 VSM

Driveshafts & Final Drive
9.6 OUTPUT SHAFT BEARING, RENEW
@ SRO 51.10.22
9.7
SRO 51.20.04
. Disconnect vehicle battery ground lead.
. Support the vehicle at the rear and remove the rear road wheel (or wheels).
9 'Match mark' the axle shaft flange to the output shaft flange and remove fixings, note camber shim.
. Thoroughly clean the area around the output shaft housing and differential case.
. Release fixings and remove output shaft assembly, discard '0' ring.
. Mark bearing retaining collar axially and drill 3 off holes 4,O mm diameter equally spaced, to a MAXIMUM depth of
. With a suitable chisel (2 Fig. 1) strike the collar across the three drilled holes to relieve tension within the steel.
CAUTION: Do not drill into the output shaft, it is not necessary to break the inside diameter of the collar. There is
no need to to split the collar when chiselling.
Using a suitable press, remove bearing and collar, remove the oil seal and discard it along with bearing.
CAUTION: The original bearing must NOT be cleaned and reused; always renew it.
Inspect the output shaft oil seal surface for damage corrosion or grooving and replace as necessary.
W:
OUTPUT SHAFT OIL SEAL, RENEW
5,O mm (1 Fig. 1).
Do not use abrasive cloth or paper to remove imperfections from the seal surface
. Using special tools JD 550-1 and 18G 134, assemble new oil seal to housing, ensuring that the seal top face is 1,8 mm below the housing top face and NOT down on the counterbore face.
Lubricate the output shaft seal diameter and oil seal lip and position the housing assembly to the shaft.
Using special tool SL 7 and a suitable press, assemble bearing to output shaft.
. Using special tool SL 7 and a suitable press, assemble retaining collar to output shaft.
= Fit the original shims and using hand pressure only to seat the assembly, check that theclearance between the output
. Using a new '0' ring and sealant on the mating faces, assemble the output shaft assembly to the differential case.
. Fitting and reassembly is the reversal of this procedure ensuring that all fixings are tightened to specification and
shaft
housing and differential case is in the range
0,05 to 0,13 mm. Shim to suit if not in this range.
See Sub
-Section 9.3 Output Shaft End Float Check.
new locking nuts are used.
Correct the final drive oil level
if required.
Issue 1 August 1994 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
__~
7 X300 VSM

With the vehicle travelling straight ahead, the valve restrictions are balanced, thus providing equal pressure on each
side of the piston. When load is applied at the steering wheel the two halves of the pinion valve are displaced making
the restrictions unequal. The differential pressure then directs the rack piston in favour of the higher pressure.
Asthe turning load is removed the pressures equalize and the steering returns to the straight ahead position, aided by suspen-
sion geometry.
The displacement
of the halves of the pinion valve (rotor and sleeve) is controlled by the elastic deformation of the
torsion bar which is concentric with the pinion and valve.
0 N
J Outlet K Outlet
L Inlet
M Inlet
N Radial groove (return)
0 Radial groove (feed) P Feedgroove ~57-278 Q Axial groove
R Axial groove S Return groove
Fig.1 Porting & hydraulic flow - LOW speed clockwise rotation
Issue 1 August 1994 X300 VSM 3