Campaign - Replace Transmission: Overview
307-11DATE 7/99
MODEL
1999 MY XK8 Range
1999 MY V8 XJ NA
VIN
031401-038608
852857-871502
ZF 5HP24 - Replace Transmission - Recall R47B
Issue:
A limited number of XK8 and V8 XJ Series vehicles within the above VIN ranges have been manufactured incorporating an automatic transmission unit in which there is a component which has the potential for failure. This is due an incorrect manufacturing process by the supplier of our transmission units. In the event of the component concerned failing in one possible manner, it has been found that the complete power train of the vehicle could lock up.
Note
It is important to emphasize that any failure of a transmission which involves complete lock up of the unit is only likely to occur at very low vehicle speed, as the transmission shifts down into 1st gear with the vehicle almost at a standstill, after being in highter gears when traveling at higher speeds.
In view of the implications of the above, particular the inconvenience to the customer, Jaguar has decided to replace the transmission on a number of vehicles within the affected VIN ranges detailed above. The vehicles affected are individual listed by VIN in this bulletin.
In December 1998, Technical Bulletin 307-08 (Service Action S476), advised that there were serious quality concerns over a quantity of automatic transmission units, as being potentially liable to failure early in the life of the vehicle. The potenial modes of failure were:
^ abnormal and excessive noise when pulling away from rest in 1st gear
^ loss of reverse drive
^ temporary loss of forwad drive, after which:
^ the transmission will revert to "limp home" mode with forward drive only
Jaguar will immedeately take the following course of action:
^ To recall for replacement of the automatic transmission unit all ADDITIONAL vehicles of which Jaguar is now aware, by means of this Recall Action R478.
AND
^ To include in the VIN listing for R478 all vehicles previously covered by Service Action S476 which have not yet been reworked.
^ To close Service Action S476. Formal documentation covering this closure will follow.
Jaguar is writing to all affected customers requesting them to contact their selling dealer or nearest dealer, as soon as possible, to arrange for the transmission assembly in their vehicle to be replaced at the earliest opportunity.
Action:
Check if the recall has already been performed on the vehicle by performing a DCS claim search and checking for a R478 label. If the recall has not yet been performed, arrange to replace the transmission assembly in any affected vehicle listed in the VIN list, or after being contacted by a Customer to whom Jaguar has written.
It is important to note that not all vehicles within the above VIN Ranges are affected - many vehicles within the complete VIN Ranges detailed above have been assembled with transmission assemblies to 'known good' condition. It should be noted, therefore, that only the vehicles listed in the VIN list need to be serviced.
The necessary Procedure is outlined in this bulletin.
Note:
XJR vehicles are NOT affected by this Service Action.
In case any vehicle listed in the VIN list has already had a replacement automatic transmission installed (particularly if the rework took place during May or June 1999) under normal Warranty, the replacement unit will have been to 'known good' condition, and it will not be necessary to perform this Recall Action. In this situation, advise the Warranty Claim Details and VIN to your warranty claims specialist, so that our records of this Recall Action may be amended accordingly.
Note:
Service action S476 will be closed effective immediately. Formal documentation to this effect will follow. Do not start a new job to replace an automatic transmission under S476 once you receive this bulletin. Any affected vehicle not yet reworked will be covered by this recall action.
NOTES ON WORKSHOP PROCEDURE ALL VEHICLES
The Workshop Procedure is fully detailed in JTIS, 1999 MY vehicles, Group 3, Section 307-01A Automatic Transmission, Removal & Installation and SRO 44-20-01. Refer also to Transmission Fluid Drain and Refill.
Replace the transmission unit complete with torque converter. Replacement transmissions are supplied overfilled with fluid, to compensate for the fluid to fill the cooling pipes and cooler.
Note:
All removed transmissions must be drained prior to return.
Check the transmission fluid level as fully detailed in JTIS, 1999 MY vehicles, Group 3, Section 307-01A, SRO 44-24-02, on completion of its installation.
Caution:
Soak the exhaust manifold nuts with penetrating oil before attempting to remove them.
VEHICLES ALREADY IN SERVICE
Since debris from a faulty component could be circulating in the transmission fluid, it is ESSENTIAL that the fluid cooler and the connecting pipes are flushed BEFORE reconnecting the pipes to the replacement transmission unit.
If a vehicle has defaulted to 'limp home' mode, connect PDU to the vehicle. Read stored diagnostic trouble codes (DTCs) in the Transmission Control Module, and delete them.
FLUID COOLER CIRCUIT FLUSHING PROCEDURE
1. While the transmission is removed, position a suitable drain container under the connectors of the fluid cooler pipes which have been disconnected from the transmission.
2. Disassemble and thoroughly clean a Snap-on� syringe (Snap-on reference YA 745) or suitable equivalent before use.
3. Connect a length of 12 mm internal diameter plastic or rubber pipe to the nozzle of the syringe. If necessary, Jaguar Part No. EBC 10850 (Hose, Evaporative Loss Flange to Filler Breather Pipe) may be used.
Caution:
Absolute cleanliness is critical during the next operations.
4. Fill the syringe from a new 1 liter container of automatic transmission fluid (ATF). Connect the hose of the syringe to the transmission cooler feed pipe (the upper of the two pipes connected to the cooler), after removing the 0-ring from the pipe. Inject the entire amount in the syringe into the cooler pipe.
5. Disconnect the syringe from the hose. Kink the hose to prevent the ATF from flowing out of it.
6. Fill the syringe with the remainder of the 1 liter of ATE. Reconnect it to the hose and inject the remaining ATF into the cooler pipe. Then allow the ATE to drain from the cooler return pipe to flush the fluid cooler and pipes.
7. Clean up any minor fluid spillage. Install new 0-rings on the cooler pipes, reconnect the pipes and tighten the union nuts.
Union nut torque: 22 Nm (16 lb.ft)
Warning:
Handling of torque converter - Use care when easing the transmission assembly away from the engine, and at all other times when the torque converter is not secured and could become detached from the transmission unit. The torque converter is heavy, particularly when still filled with fluid.
DRIVE PLATE TO TOROUE CONVERTER BOLTS
ALWAYS replace the drive plate to torque converter bolts.
SELECTOR LEVER - CORRECT OPERATION
Correct adjustment of the gear selector cable may be verified by ensuring that the appropriate positions on the J-gate illumination module are correctly illuminated when the lever is adjacent to that position.
FLUID LEVEL SETTING
The correct quantity of automatic transmission fluid has been supplied prefilled in the transmission unit and it should not require adjustment. Should it be necessary to recheck the level due to spillage, then follow JTIS 6 procedure, Section 307-1 A, SRO 44-20-02. Note that, as with all current Jaguar automatic transmissions, the level is checked with the engine running.
INSTALL RECALL LABEL
Write the date and your dealer number on the R478 authorized modification label (Illustration 1). Apply the label to the underside of the hood on V8 XJ Series vehicles. Apply the label to the B-pillar on XK8 vehicles. (This label will immediately indicate to any other dealer that the vehicle concerned has already been rectified).