All in - pulling the 4.6 engine and trans to fix oil leaks once and for all

[RRPhil]

Nearly all of the phosphor bronze bushes in the 5HP24 also double-up as hydraulic seals so any signs of wear (increased clearance) is bad news. The bush in this carrier however is just a ‘radial steady’ for the B-clutch drum & C-clutch hub and its condition isn’t therefore critical. The bore should measure around 30 or 40 microns over 66mm so if it’s not too worn I shouldn’t worry about it.

Regarding the clutch pack clearances, if you have an early version of the Repair Manual, the chances are that the recommended clearances have now changed. Also, different models of the 5HP24 have different numbers of friction plates in the same clutch pack depending on the required torque capacity. Take for example the D-brake setting specification. Your Manual may quote 1058 700 067 ‘Version B’ which is the old 4 plate Jaguar arrangement. Your ‘034’ model for the 4.6is has 5 plates in the D-brake (i.e. ‘Version D’) and the latest setting specification is 1058 700 143 and the clearances have changed (1.93 to 2.22mm for new plates, 1.93 to 2.38mm for bedded-in ones).



To be honest I’d avoid becoming too distracted from the important stuff if I were you. The fact is if the plates aren’t worn then the clearance settings will not have changed from when the snap rings were selectively fitted at the factory. Any small changes will have been compensated for by the long-term adaptions in your transmission ECU (fixing shift times through modulating the clutch pressures) so, provided the plates are in good condition - which yours are* - I personally wouldn’t worry about this aspect. I’d say it was more important to get everything apart to check all the seals, etc. and find the cause of the failsafe message.

Phil

*Typically A-clutch friction plates measure 1.55mm thickness & B-clutch ones 1.61mm. You’re measuring 0.061” and 0.064” (will you guys ever go metric?) so yours are spot on.

[stunt]

Thanks again Phil for your excellent advice!

Yes, my manual is very old, dated 98/08/01 which I believe translates to 1/8/1998 for Americans.

I agree with you the metric system should be embraced here in the states, but I doubt that will happen in my lifetime. I was strange coming over here and having to adjust from using the metric system to standard.

Ok, I'll not worry about the friction plates then and move on to disassembling the rest of the transmission. Hopefully I'll find a direct cause of the failsafe message!

I picked up a 8' stainless work bench top that was on sale at Sears, and will be building a solid frame for it tomorrow so that I can move my transmission disassembly operation to a proper place. I think my old office desk has outlived its use for this purpose. The lamination is starting to come off big time and the surface is very uneven. That 8' folding table if too flimsy for any real automotive work, but great for lots of other stuff.

[RRPhil]

Yes, I built my workbench from scratch (from wood but with a metal sheet top) and that was specifically so I could provide enough space to store the winter tyres/wheels for my Range Rover underneath. Unfortunately I opted for a mild steel rather than a stainless steel top (I’m such a cheapskate) so if I haven’t used it for a while I do have to clean off a surface layer of rust!





Phil

[stunt]

Looks good Phil!

Speaking of rust, once I clean the parts, should I coat them in something to prevent surface rust? Around where I live it gets very humid in the summer time and I only run the A/C in the shop when I'm in there.

Maybe surface rust is a non-issue (obviously not the aluminum parts) but not 100% sure on the rest. At the pace I'm going, the cleaned pieces are likely to sit for a while before final assembly.

[RRPhil]

I must admit that I tend not to clean the old fluid off the steel parts until I know I’ll be refitting them within a few days. Anything over 45% relative humidity will cause these components to rust scarily quickly – especially things like the clutch steel plates & drums/hubs. Once cleaned I ‘paint’ all the steel parts with fresh transmission fluid (also a good opportunity to inspect the parts thoroughly) and bag them if I have to store them for any length of time.

Phil

[RRPhil]

I should have mentioned, in case it isn’t obvious, that the friction plates in the A & C clutches are the same part and the friction plates in the B, D & E clutches are all the same part so the plate thicknesses already mentioned apply to these clutches too. The F-brake friction plates (the F-brake assembly, incidentally, is nicked straight from the old ZF 5HP30 and hence has part numbers prefixed by ‘1055’ rather than ‘1058’) should measure around 1.60mm.



Phil

[stunt]

Thanks again Phil for the expert advice! I'll wait to clean the parts then until I'm ready. Glad I asked!

Started on the shop bench tonight. Here's the stainless work surface. It is 96" x 24" and 1.5" thick (double 3/4" MDF core). It comes in at around 150lbs, so very hard to move around by myself.



I plan to add another 12" (double 3/4 MDF core as well) at the back so the total worksurface will be 96" x 36".

I have cleared a previously unused back corner of the shop for the shop bench. There's just over 96" between the red truss and air compressor, which stick out about 36", so it should be a perfect fit.



I started gluing the end structures as seen here from the zoomed out view of bay 4 of the shop.



It will be so nice to finally have a work bench in the shop after 14 years! Don't know what I was thinking not doing this before...

Shot across the shop while I had the camera out



And outside shop. I added the 2 16' W x 36' D bays last year and they are already stuffed. Lol

[e30cabrio]

I am jealous!

I have a little 3 hp IR compressor. Plenty for my little air tools, IR Ti2135 gun & 1105 ratchet.

Thanks for all the updates & pics!!

[puddinboo]

I would like just 1 of those bays and I`ll be a happy . stunt thx again for all the great pics. it looks interesting to rebuild tranny`s ,but alot of patience though.

[BigBlack48is]

Wish my garage looked like Stunt's!!