Its official , my gearbox is stuffed ,

[Brakebuster]

still waiting for the refurb kit from America , expecting it tomorrow


so while i was bored , i refurbished the torque converter ,

3377 by MyPix

as far as i know, the internals are fine and will get a good flush off the car, but the outside has only got to smell moisture and rusts making it look bad, so i painted it like the Americans do !


BB

[Brakebuster]

so , the kit has arrived, and i even bought a second kit on ebay because it was very cheap......

i have also treated myself to some new workshop equipment including a bush and bearing drift set , and a full set of digital callipers and dial gauges and magnetic stand

3462 by MyPix

new copper alloy bush and gearbox end extension seal bashed home, lol , that bit can now be put to one side,

3461 by MyPix

measuring the original end float of the pump in the box,i could tell by the feel it was way too much , but i needed to know how much so i can get the correct shims to bring it back to tolerance , its suppose to be between 15 and 30 thou , 0.72mm max( 30 thou )
this is setup and zero'd prior to measuring, the electro magnetic base makes everything steady

3463 by MyPix

as you can see , its way out, but is a starting point , all new components should bring it back a little, and then a shim will bing it to tolerance

3464 by MyPix

and for those still thinking in the stone age........ ( that should read a max of 0.030 , not 0.0415 )

3465 by MyPix

with the end float measured , i could proceed with stripping out the internals, this means removing the pump on the front, its in there tight but Jaguar kindly threaded two of the bolt holes to a assist, a puller would work but i only had metric threads, so i bashed it with a nylon hammer until it gave up , and then pulled it over the inner drive shaft ,

3466 by MyPix

i then removed as per my instruction book ( another thing i had to buy ) all the internal clutches and drive section, this is them all on the rolling trolly ( christmas present ) ready for inspection , cleaning and then rebuild before installing back in the case

3467 by MyPix

and thats it, a fully stripped case ready for jet washing and rebuilding

3468 by MyPix

a quick inspection of the friction material showed definite burning as a dark brown/black ring on the dark red friction surface, i will take a pic , but its too late now


thanks for hanging in there , but i can't just say i took it to bits and put it back together , lol

BB

dont worry , i won't let the bastards bring me down

[J44EAG]

Serious Big Boys stuff there Vince.

Nice tool sets. No mucking about with that lot.

Watching closely with interest.

Mike

[davidr]

Vince - impressive stuff. I don't mind having a go but bloody hell!
Also jealous of the drift set. Where did you get it?

[Brakebuster]

so , today i degreased and then jet washed the transmission case, and then used the air line to blow out the water from all the nooks and crannies . the case can look like its still dirty , but that is silver paint over cast aluminium thats all.

3473 by MyPix

next is to drive out the rear case bushing using a hardened steel punch being careful not to score the case ,

3470 by MyPix

removed bushing

3471 by MyPix

new bushing drifted in with my set and using a little thread lock to set the bushing in the case , as they can spin out causing issues , excess thread lock was then wiped away.

3472 by MyPix

next is the kick down connector , cleaned up and a new seal with a little petroleum jelly to aid installation , its popped into the case , old seal is next to it , which was hard....

3474 by MyPix

installed , simple push fit,

3480 by MyPix

next is the manual shift case seal , its shown on another set of drifts for smaller items,
3476 by MyPix

set into case

3477 by MyPix

then the park brake pawl , just cleaned up , spring fitted and connecting rod and lever fitted , along with the manual gear selector cam

3481 by MyPix

selector cam

3482 by MyPix

all in situ

3483 by MyPix

thats it for this weekend as the F1 GP is on soon


oh , i did say i would show you what a burned clutch looked like

3479 by MyPix

BB

[Brakebuster]

so, its sunday , the F1 GP is over, and i got bored, lol

so i decided to refurbish the final drive section of the box, this is the output shaft planet and sun gearing stripped down

3512 by MyPix

old bushing removed, and new one installed

3513 by MyPix

not very complicated , so with new bushings and new o-rings installed,and a new silencer ring , along with new torrington bearings lubricated its popped back together ready for the next part

3514 by MyPix

planet gear housing bushing removed and new one fitted with some lock tight, and then a new sprag one way roller fitted ( can be seen in next picture )

3515 by MyPix

then , with the rear band soaked in ATF and fitted into the case, the whole final drive section is dropped into the case with the middle sun gear fitted , ready for the centre support , this is in bits on the bench ready for rebuild in the next instalment , lol

3516 bMyPix


BB ( i must be mad..... )

[J44EAG]

This would test my confidence, Vince.

I raise me top hat to you.

Mike

[Brakebuster]

so , the next instalment

the central support refurbishment, this is a drum with a spring valve inside and a large bushing in the centrall shaft , new seals to the piston , new torrington bearings, new bushings and all put back together with a ' brass ' thrust washer rather than an original plastic one,

3531 by MyPix

up the other way showing the four slip seals, the piston is mounted under the spring retainer , , the new bushing was pushed in with my 12 tonne press, as its about 100mm long,

3534 by MyPix

then this whole unit is dropped into the case making sure its seated correctly and the oil supply holes are in the right place and the chamfered retaining ring is snapped in making sure its the right way up

3535 by MyPix

then the first of the steel clutch sections is dropped in,

3540 by MyPix

followed by a friction plate and then a steel and friction plate etc , and then finally the thick retainer followed by a snap ring

3539 by MyPix

i have upgraded from a three clutch to four clutch system for a more positive gear change , and a quicker change , friction material soaking in ATF before being installed

3538 by MyPix

and finally all stacked up and held in with a snap ring,

3541 by MyPix

BB

[J44EAG]

Superb work, Vince.

Wonderful to see what is inside one of these units and to watch it being built back up.

Keep at it.

Mike

[Brakebuster]

Interlude


I'm on holiday
Lol
BB

[Brakebuster]

right. onto business ,

the next step was to re-bush the central drive , and install it into the central support ,
central shaft,

3920 by MyPix

new bushes installed ,

3921 by MyPix

installed into the into the central carrier with the clutch pack already installed

3922 by MyPix

fully installed and located in the main sun gear lower in the box along with the front band

3923 by MyPix

next was to disassemble the intermediate clutch ,

3929 by MyPix

i had to think of a way to compress the valve springs to remove the cir clip retaining the collar ,
so i cut up an old welding wire spool that is made of heavy duty abs , allowing me to access the clip while compressed

3924 by MyPix

the component parts of the clutch ,

3927 by MyPix

removing the valve from the drum , showing the seal

3928 by MyPix

then it was a full clean , install new seals all round and build back up ,

3929 by MyPix

and installed in the case

3930 by MyPix

onto the front drum , pretty much the same as the intermediate drum in process, but this has the main drive shaft installed

3931 by MyPix

retaining ring removed

3932 by MyPix

and disassembled for cleaning and new seals

3933 by MyPix

3935 by MyPix

new seal installed

3936 by MyPix

and all put back together and dropped into the case, final thing was the pump , as i was very messy , and concentrating, i forgot to take any pictures, lol, but the pump is the disc shaped item in this picture

3467 by MyPix
remove all the front bolts, and separate, inspect for condition, and replace internal seals, while assuring correct alignment when putting back together , and then drop into the case, you then have to check the end float, and remove for adjustment if required using the pre made shims in the pack

BB

[J44EAG]

Superb work, Vince.

Ingenious reuse of the welding wire drum. You must have been watching Blue Peter!

You can`t be far off finished now.

Mike

[Brakebuster]

guess what

i actually have a Blue Peter badge


BB

[Brakebuster]

right ,

with all the spiny things shoved into the case, its time for the valve block , the bit that sits over the filter when looking at it in the car, the valve block is the brains of the system , and controls the pressures and flows of the fluid within the case, there are several different types , Jaguar used the manual select first and second gear and full auto , but there were safety features to stop the box from being damaged, so even if you selected first , the box would change up if IT felt it needed to , these can be over ridden by altering the valve block setup with modifications and different valve block paper gasket sets ,

i have stuck with a stock setup , well almost , as i have an adjustable modulator , and removed the accumulator assist spring within the valve block for this function , and also some of the fluid check balls have been omitted ,

this is the valve block with its component parts removed ready for cleaning

4018 by MyPix

this is the valve block with all the parts refitted from the previous picture, its a simple clean and check , lubricate and reassemble task , you can just see the pistons within the block in place

4001 by MyPix

next is the accumulator piston for the front band , with the adjustable vacuum modulator you can omit the spring, this makes for a slightly crisper shift , these are the component, a new teflon seal was fitted prod to fitting

4002 by MyPix

this picture shows where the spring should go , i did not fit this spring, it is a widely accepted modification to improve response

4003 by MyPix

then its the fluid check balls , these are simple ball bearings of a certain size, six are normally fitted for ' comfort ' two are the minimum required for race shifting at full pressures, i opted for five check balls in the locations shown

4000 by MyPix

next is to offer up the gasket set and spacer plate, along with the detent solenoid which is for the kick down function , this was all placed on the case and held in place while the detent solenoid was tightened down

4005 by MyPix

i then removed the bolts that are protruding and offered up the valve block while locating the two top oil flow pipes to the case, and the manual select valve onto the manual shifter cam with the spring retainer in place

4010 by MyPix

next is the oil pickup tube, its common practice to install this tube with two O rings fitted to ensure correct pickup , belt n braces and all that.......

4011 by MyPix

and then its the filter

4012 by MyPix


4013 by MyPix

i then temporarily fitted the sump pan using a lesser cork gasket , i plan to paint the case and fit a nice chrome ' finned ' sump , but the original one will stop things getting damaged for now

BB

[Brakebuster]

with the work bench cleared and cleaned ( a bit ) it was time to check the end float of the rebuilt box

this time i sat the whole box on the bench resting on the pan , and set the dial gauge on the bench its self

4020 by MyPix

i chose a new shim to reduce the overall play i had to start with before the stripdown as mentioned in the first post, but it was not however enough , i then chose another shim, which was too much , in fact there was no movement at all , lol

the kit supplies you with eight shims of differing thickness just for this task , i finally chose the correct shim , the thing is replacing the shim means removing the pump from the case each time, then tightening it down each time to check the end flood

but i eventually ended up with this

4014 by MyPix

tolerance is between 15 and 30 thou , as you can see , i got it to 16.5 thou , so not bad for a home build i think , lol

BB