Content .. 397 398 399 400 ..

Jaguar X-Type Sedan and Estate (Wagon). Manual - part 399

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Published: 11-May-2011

Manual Transmission/Transaxle and Clutch - General Information - Manual
Transmission and Clutch

Diagnosis and Testing

Inspection and Verification -Clutch

As fault diagnosis starts when repairs are taken on, the following procedure is recommended:

1. Verify the customer concern by operating the system.

2. Visually inspect for obvious signs of mechanical damage.

Visual Inspection Chart

Mechanical

Electrical

Transmission oil leak
Missing screws or nuts

3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next

step.

4. If the concern is not visually evident, verify the symptom and refer to the Symptom Chart.

Inspection and Verification - Manual Transmission

The following checks should be carried out before repairing or installing a new transmission:

Transmission Noise

If transmission noises are reported, check the transmission fluid level. If damage has occurred due to a lack of fluid, install a new
transmission.

Oil Leakage

Check that the leaking fluid is actually transmission fluid and not hydraulic fluid (from the hydraulically operated clutch) or engine
oil.
Check the transmission fluid level and, as necessary, drain off any excess fluid.
Clean the transmission and the adjacent areas carefully before the road test.

Symptom Chart - Poor gear shifting

Symptom Chart

Symptom

Possible Sources

Action

Significant effort required when downshifting or
synchronizer crashing

Gear synchronization is inadequate.

Check oil level.
Check gear linkage.
INSTALL a new
transmission.

Gear jumps out of engagement while driving

Worn or broken synchronizer components.
Manufacturing error (incorrect gear wheel toothing or
synchronizer ring).

INSTALL a new
transmission.

Gearshift problems in different gears (stiff or
partially seized)

Gear linkage.

Check oil level.
Check gear linkage.
INSTALL a new
transmission.

Brief scratching noise during gear shifting

Inadequate gear synchronization.

Check oil level.
Check gear linkage.
INSTALL a new
transmission.

Symptom Chart - Oil leakage

Symptom Chart

Symptom

Possible Sources

Action

Leak from transmission
housing

Leak from breather.

CHECK oil level.

Leak from fill plug.

TIGHTEN fill plug.

Leak from drain plug.

TIGHTEN drain plug.

Sealing lip of the output shaft oil seal
damaged.

INSTALL a new output shaft seal and drive flange if seal is
damaged.

Oil leaking from the selector shaft oil seal.

INSTALL a new selector shaft seal.

Leak from crankshaft rear seal.

INSTALL a new crankshaft seal.

Leak from clutch hydraulics.

For additional information, refer to Pinpoint Test H.

Sealing lip on input shaft damaged.

INSTALL a new input shaft seal.

Symptom Chart - General Concerns

Symptom Chart

Symptom

Possible Sources

Action

Clicking noises in
reverse gear

Gear wheels.

RUN the vehicle on wheel free ramp to establish that the noise is coming
from the transmission. If the noise is coming from the transmission
INSTALL a new transmission.

Gear wheels banging
when shifting

Damaged clutch.

CHECK the clutch is clearing correctly.
No-For additional information, refer to Pinpoint Test A.
Yes-CHECK transmission oil level. If transmission level is okay INSTALL a
new transmission.

Selector forks or synchronizer rings.

INSTALL a new transmission.

Noises in the forward

Transmission fluid level low

FILL the transmission with correct amount of fluid.

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gears

The engine/transmission assembly is
in contact with the chassis/body.

INSPECT for points of contact or damaged engine/transmission isolator,
support insulator.

Engine/transmission flange bolts.

TIGHTEN the transmission flange bolts. For additional information, refer
to 308-03.

Input and output shaft bearings.

INSTALL a new transmission.

Gears jump out of
engagement

Engine/transmission support
insulator.
Internal components.

REPAIR or INSTALL new components as necessary.
INSTALL a new transmission.

One of the gears
cannot be selected

Gearshift linkage malfunction.

CHECK gearshift linkage correctly attached to transmission case, sector
arm and the rear mounted to body.
CHECK gearshift linkage functions correctly.

Transmission internal selection
problem.

INSTALL a new transmission.

Gears jumps out of
engagement

Gearshift linkage fault.
Internal selector mechanism loose.
Synchronizer fault.

CHECK gearshift linkage for correct function.
INSTALL a new transmission.
INSTALL a new transmission.

Clattering, or rattling
noises

Gearshift mechanism foul to body.

Make sure that the gearshift mechanism is correctly located onto the
gearbox.
Make sure that there are no components fouling the gearshift linkage.

Gearshift lever joint.

CHECK free play in bearing between the lever and support housing, and
between the lever and shift arm.

Gearshift lever knob loose.

TIGHTEN the gearshift lever knob or, INSTALL a new knob as necessary.

Gearshift linkage has
excessive play

Gear lever bearing worn.
Gearshift selector rod assembly
damaged or worn

CHECK free play in bearing. INSTALL a new if necessary.
INSTALL a new gearshift selector rod assembly

Gearshift linkage does
not operate freely

Excessive friction in lever bearing.
Gearshift selector rod assembly
damaged or worn
Possible fault in transmission

INSTALL a new lever bearing.
INSTALL new gearshift selector rod assembly
INSTALL new transmission.

Symptom Chart - Clutch

Symptom Chart

Symptom

Possible Sources

Action

Clutch slippage

Clutch pedal free play.
Sticking clutch pedal.
Diaphragm springs.
Clutch pressure plate.
Clutch disc facing.
Hardened or oiled clutch disc facing surface.
Flywheel.

GO to Pinpoint Test A.

Excessive temperature.

ALLOW the clutch to fully cool.

Slave cylinder sticking.

CHECK slave cylinder travels freely over
its complete travel.

Adjuster ring at fully worn position.

INSTALL a new clutch drive plate.

Clutch chatter or
shudder

Engine mounts.
Oil on clutch disc facing.
Diaphragm springs.
Clutch pressure plate.
Clutch disc facing.
Flywheel.

GO to Pinpoint Test B.

Clutch drag

Insufficient brake fluid.
Air in hydraulic system.
Clutch pedal free play.
Diaphragm springs.
Clutch disc.
Clutch disc splines.
Oil on clutch disc facing.

GO to Pinpoint Test C.

Insufficient clutch pedal travel.

Make sure the clutch pedal has its full
range of travel.
Make sure the clutch pedal returns to
the fully released position and the
reservoir is full.

Clutch pedal
pulsation

Clutch and brake pedal pivot shaft not correctly lubricated.
Flywheel.
Damaged springs in pressure plate.

GO to Pinpoint Test E.

Release bearing noisy or worn.

INSTALL a new release bearing.

Cover assembly.

CHECK run out of clutch cover. INSTALL
a new clutch cover.

Clutch pedal
related vibrations

Engine component grounding against frame.
Accessory drive belt.
Flywheel bolts.
Flywheel.
Imbalanced clutch pressure plate.

GO to Pinpoint Test E.

Hard shifting

Insufficient brake fluid.
Clutch pedal free play.
Manual transmission concern.

GO to Pinpoint Test F.

Excessive noise

Clutch pedal free play.
Clutch release bearing.
Poor lubrication of clutch release bearing.
Pilot bearing.
Excessive crankshaft end play.

GO to Pinpoint Test G.

If the noise is heard from the transmission when the engine is started and
switched off with the clutch engaged, and the noise disappears if the
clutch pedal is depressed.

INSTALL a new flywheel.

Fluid leakage

Clutch master cylinder.
Clutch slave cylinder.
Clutch hydraulic tubes.

GO to Pinpoint Test H.

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PINPOINT TEST A : CLUTCH SLIPPAGE

TEST

CONDITIONS

DETAILS/RESULTS/ACTIONS

A1: TEST CLUTCH SLIPPAGE

Lock wheels and put parking brake on .
Start the engine and engage 4th gear.
Run the engine at approximately 2000 rpm.
Release clutch pedal slowly.

Does the engine stall when the clutch pedal is fully released?
Yes

Clutch OK.

GO to A2

A2: TEST CLUTCH FOR CLEARING

Start engine, fully depress the clutch pedal, partially engage reverse gear, slowly engage clutch until a grating noise
is heard, depress the clutch slowly until grating stops.
Measure pedal travel from the pedal to the floor.

Is the measurement between 25mm and 45mm?
Yes

GO to A3

GO to B3

A3: TEST FULL PEDAL TRAVEL

Measure the clutch pedal travel from fully up to fully compressed.

Is the measurement between 140mm and 150mm?
Yes

GO to A4

CHECK clutch pedal for obstructions. TEST the system for normal operation.

A4: TEST CLUTCH PEDAL

Check lubrication.

Is the clutch pedal shaft sufficiently lubricated?
Yes

GO to B3

Lubricate clutch pedal shaft.

PINPOINT TEST B : CLUTCH CHATTER OR SHUDDER

TEST

CONDITIONS

DETAILS/RESULTS/ACTIONS

B1: TEST CLUTCH CHATTER OR SHUDDER

Start the engine and engage 1st gear.
Run the engine between 1200 rpm and 1500 rpm.
Release clutch pedal slowly.

Does the vehicle jerk when it starts off?
Yes

GO to B2

Clutch OK.

B2: TEST ENGINE/TRANSMISSION SUPPORT INSULATOR

Check engine/transmission mountings, support insulators for damage or loose bolts.

Are the engine/transmission mountings, support insulators loose or damaged?
Yes

TIGHTEN the bolts or INSTALL new engine/transmission mountings as necessary. TEST the system for normal
operation.

GO to B3

B3: TEST CLUTCH PRESSURE PLATE

Remove clutch pressure plate.

Does the clutch pressure plate have signs of wear or damage?
Yes

INSTALL a new clutch pressure plate.

GO to B4

B4: TEST CLUTCH FRICTION DISC

Visually check the clutch friction disc.

Is the clutch friction disc oil-fouled or does it have burn marks?
Yes

INSTALL a new clutch friction disc. TEST the system for normal operation.

CHECK the flywheel.

PINPOINT TEST C : CLUTCH DRAG

TEST CONDITIONS

DETAILS/RESULTS/ACTIONS

C1: CHECK BRAKE FLUID LEVEL

• NOTE: The hydraulic clutch fluid is supplied from the brake master cylinder.

Check the brake fluid level.

Is the brake fluid level between the MAX and MIN marks on the brake fluid reservoir?
Yes

GO to C2

FILL brake fluid, the brake and clutch system for leaks. Test system for normal operation.

C2: TEST CLUTCH PEDAL FREE TRAVEL

Operate clutch pedal manually to the point of resistance and release.
Measure pedal travel.

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Is the measured dimension within 15 mm?
Yes

INSTALL a new clutch pressure plate. TEST the system for normal operation.

GO to B3

PINPOINT TEST D : CLUTCH PEDAL PULSATION

TEST CONDITIONS

DETAILS/RESULTS/ACTIONS

D1: TEST CLUTCH PEDAL

Check lubrication.

Is the clutch pedal shaft sufficiently lubricated?
Yes

CHECK the flywheel.

LUBRICATE the clutch pedal shaft. TEST the system for normal operation.

PINPOINT TEST E : CLUTCH RELATED VIBRATIONS

TEST

CONDITIONS

DETAILS/RESULTS/ACTIONS

E1: CHECK FOR ENGINE COMPONENT GROUNDING

Raise and support the vehicle.
REFER to: Jacking (100-02 Jacking and Lifting, Description and Operation).
Check the engine mountings for grounding on the body frame.
Check the exhaust manifold or other engine component grounding on the body or frame.

Is there evidence of grounding on body or frame?
Yes

REPAIR or INSTALL a new as necessary. TEST the system for normal operation.

GO to E2

E2: CHECK FOR ACCESSORY DRIVE VIBRATIONS

Feel accessory vibration at clutch engage/disengage when engine torque changes.
Disconnect the accessory drive belt and check for vibration.

Does the vibration stop when the drive belt is removed from the engine?
Yes

REPAIR or INSTALL new accessory drive belt components. REFER to:

Accessory Drive - 4.2L/2.5L/3.0L (303-05 Accessory Drive, Diagnosis and Testing),
Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and Harshness, Diagnosis and Testing).

GO to E3

E3: CHECK FOR RELEASE BEARING NOISE

Start the engine.
Depress and hold clutch pedal.

Is a whirring, grating or grinding noise present?
Yes

INSTALL a new clutch slave cylinder. . TEST the system for normal operation.

GO to E4

E4: INSPECT FLYWHEEL

Remove the transmission.

Five speed transmission -
REFER to: Manual Transmission (308-03 Manual Transmission/Transaxle - Vehicles W ith: 5-Speed Manual
Transmission, Diagnosis and Testing).
Six speed transmission -
REFER to: Manual Transmission (308-03 Manual Transmission/Transaxle - Vehicles W ith: 6-Speed Manual
Transmission, Diagnosis and Testing).

Inspect for loose flywheel bolts.
Carry out flywheel runout check.

Is the flywheel OK?
Yes

DIAGNOSE engine vibration concern.
REFER to: Engine - 4.2L/2.5L/3.0L (303-00 Engine System - General Information, Diagnosis and Testing).
or
REFER to: Engine - 2.7L Diesel (303-00 Engine System - General Information, Diagnosis and Testing).

TIGHTEN flywheel bolts or INSTALL a new flywheel. Test the system for normal operation.

PINPOINT TEST F : HARD SHIFTING

TEST CONDITIONS

DETAILS/RESULTS/ACTIONS

F1: CHECK FLUID LEVEL

• NOTE: The hydraulic clutch fluid is supplied from the brake master cylinder.

Inspect the fluid level in the brake master cylinder reservoir.

Is the fluid within the MAX and MIN level marks?
Yes

GO to C2

FILL brake fluid, CHECK for leaks in the clutch and brake system. TEST the system for leaks.

PINPOINT TEST G : EXCESSIVE NOISE

TEST

CONDITIONS

DETAILS/RESULTS/ACTIONS

G1: CHECK TRANSMISSION NEUTRAL POSITION

Start the engine and run it in neutral.
Depress clutch pedal fully.

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