Campaign - Transmission Replacement: Overview
7-16DATE 7/99
MODEL
1999 MY XK8 Range
1999 MY V8 XJ NA
VIN
See VIN list
ZF 5HP24 - Replace Transmission - Recall R478
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 lockup 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 higher gears when traveling at higher speeds.
In view of the implications of the above, particularly 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 individually 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 potential modes of failure were:
^ abnormal and excessive noise when pulling away from rest in 1st gear
^ loss of reverse drive
^ temporary loss of forward drive, after which:
^ the transmission will revert to "limp home" mode with forward drive only
Jaguar will immediately 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.
Refer to technical bulletin 307-11 for the technical procedure.
LIST OF AFFECTED VEHICLES AND MARKETS
Parts Information:
DESCRIPTION PART NO. QTY/VEH
Automatic Transmission w/torque converter,
supplied pre-filled NNE44OOAA/NK 1
Seal - oil cooler pipe EBC 4899 2
Bolt - torque converter to drive plate EAC 5580 3
Gasket - exhaust manifold to catalytic converter EAZ 2050 2
Nut, catalytic converter to downpipe (VDP only) FN 110041/J 4
Nut, catalytic converter to manifold JZN 100021 8
Gasket - catalytic converter to front
downpipe (VDP only) NNC6764AB 2
Oil, auto transmission (1 liter container) JLM 20237 See note
Note:
Transmissions will be supplied overfilled, to compensate for the small loss of ATF when the cooler pipes are disconnected and reconnected. No ATF will normally be required for unsold vehicles in stock. For vehicles which have already been run in service, 1 liter of ATF is required to flush the oil cooler and connecting pipes.
RETURN OF REMOVED TRANSMISSIONS:
USA dealers
For this recall, return all removed transmissions, complete with torque converters, to ZF USA as soon as possible, reusing the packaging in which the new units were supplied. Ensure that the procedures below are followed before returning the transmission.
^ Torque converters should not be removed from the transmissions. Ensure that the torque converter retaining strap is transfered over to the removed unit.
^ Drain all oil before repacking for transit. Remove the drain plug from the sump pan, drain the oil and reinstall and tighten the drain plug.
^ Transfer all shipping plugs from the new unit to the removed unit.
^ All removed gaskets and seals along with all drained transmission oil should be discarded.
^ Make a copy of the shipping ticket and aflach it to the bar code label to ensure proper credit on the claim. Send both to:
Jaguar Cars
Att: Warranty Parts Return