Service 3.4 L - Terry`s Jaguar Parts
Contents
1. Spares Bulletin No D 26 refers Jaguar Cars Limited 2005 JAGUAR Number F 14 Section Gearbox and Overdrive Page 1 of 3 Date September 1966 COMPACT OVERDRIVE UNIT Models affected Overdrive Unit number 4 2 Mark 10 25 60552 3 4 3 8 S Models 28 60572 3 4 3 8 Mark 2 28 61740 3 4 Mark 2 28 61743 In isolated instances slipping in reverse and sticking in overdrive conditions have occurred in the above units To overcome these faults a modification kit Jaguar Part No 11301 Laycock Part No 65980 is now availableand consists of the following items Jaguar PartNo Item Laycock Part No 11303 Clutch return spring 65966 Set of 6 11304 Packing washer for accumulator 62023 spring 1 10968 Operating valve 1 60686 C 5965 Tab Washer 4 65300 Fitting Instructions Remove the engine and gearbox as a unit from the car as detailed in Section B of the appropriate Service Manual Remove six nuts and lockwashers and detach the overdrive unit from the adaptor plate attached to the rear end of the gearbox Release the tab washers and remove four nuts tab washers and the two operating piston bridge pieces Release the solenoid securing screws to allow the front casing of the unit to be removed fcont d Jaguar Cars Limited 2005 Bulletin F 14 September 1966 Page 2 of 3 Remove the four nuts and washers and separate the front and rear casings Lift out the clutch sliding member complete with thr2. If on dismantling a low mileage unit which is just outside the warranty period it is found subseguent to examination that an e t of warranty claim may be justified the unit must be completely re assembled and returned t o these works in accordance with the normal warranty procedure No claim will be considered if the unit is incomplete tee Jaguar Cars Limited 2005 JAGUAR Number F 6 Section Gearbox and Overdrive Sheet 1 of 1 Date September 1963 BENCH TESTING THE OVERDRIVE SOLENOID All Models Tt should be noted that on no account must a solenoid be energised before fitting to the car As the solenoid plunger has no load to carry the impact of it opening the contact points will be sufficient to bend the contact arm preventing the points from opening Jaguar Cars Limited 2005 JAGUAR Number F 7 Section Gearbox and Overdrive Sheet 1 of 1 Date January 1964 STICKING IN 1ST GEAR Ad cynehromestr yearbox Model s If difficulty is experienced with sticking in first gear the following procedure should be adopted Remove the console trim and gearbox tunnel cover then the top cover of the gearbox It may then be necessary to use two levers to ease the 1st speed gear forward on the 2nd speed synchro sleeve Ignore the slight damage which may have occurred to the stop pin on the 2nd speed synchro sleeve With the gearbox top cover on the bench remove the selector housing by taking o
3. been fitted between the bush and Lever Securing nut and the above serial numbers record the commencement of thc modification The retaining washer may if desired be fitted to gearboxes prior to the above numbers as follows Remove the console and gear lever grommet as detailed in the appropriate Service Manual On 1 2 E Type cars it will also be necessary to remove the tunnel cover Remove the retaining nut at the base of the lever Fit the washer with the hollow face to the bonded rubber bush and refit the retaining nut Refit the gear lever grommet and consolc Rescal the tunnel cover on 4 2 E Type cars with a good quality sealing compound to prevent the entry of water Spares Bulletin D 31 refers Jaguar Cars Limited 2005 JAGUAR Number F 16 Section Gearbox and Overdrive Sheet 1 of 1 Date March 1967 COMPACT OVERDRIVE UNITS ALL MODELS A recent modification has been introduced to the Adaptor Plate fitted to Compact Overdrive units Whilst this modification in no way affects interchangeability in consequence the Part Numbers remain unchanged it is ESSENTIAL that in the future only the new item is used with replacement units fitted to a car It iS IMPORTANT that all Compact Overdrive Units which are to be returned undereguarantee craim should be removed from the gearbox COMPLETE WITH THE ADAPTOR PLATE and returned to the Works as an assemhly IT IS EMPHASISED THAT FAILURE TO ADHER
4. the plug This is additional to any which may already be fitted cont d Jaguar Cars Limited 2005 Bulletin F 14 September 1966 Page 3 of 3 Refit the plug and sealing washer Note The addition of packing washer 11304 62023 will raise the hydraulic pressure to Unit 28 60552 540 560 P S I Unit 28 60572 490 510 P S I i Unit 28 61740 490 510 P S I Unit 28 61743 480 500 P S I Reassemble the unit to the engine ard refit to the car The modifications referred to in this Bulletin have been introduced in production build by Laycock Engineering Ltd commencing with Unit 28 60552 1342 4 2 Mark 10 Unit 28 60572 8407 3 4 3 8 S type Unit 28 61740 2647 3 4 3 8 Mark 2 Unit 28 61743 1116 2 4 Mark 2 t Spares Bulletin D 30 refers Jaguar Cars Limited 2005 JAGUAR Number F 15 Section Gearbox and Overdrive Page 1 of 1 Date December 1966 GEAR LEVER RETAINING WASHER Standard and Overdrive Transmission Models affected Commencing Gearbox Numbers 2 4 Litre Mark 2 ee an ae 3 4 Litre Mark 2 JCN 3467 3 8 Litre Mark 2 3 4 Litre S Type 3 8 Litre S Type TED GEN 2 4 2 Mark 10 JZN 923 472 E TPype F37H367 E3 7920 2 E Type Open EJ 7920 4 2 Ek Type 242 EJS 7920 Isolated instances have occurred where the bonded rubber bush at the bottom of the gear l ver has albowed the lever to become detached To prevent this a dished retaining washer has now
5. 1 180188 and 169285 3 8 litre Mark 2 234125 224150 plus 234079 to 234089 The engine idling speeds and recommended lubricants are as stated on Service Bulletin F 9 DISMANTLING Mark 2 Models Removal of Clutch Housing Detach the springs and remove the carbon thrust bearing Unscrew the two nuts and remove the clutch slave cylinder Remove the allen screw push out the fulcrum pin and detach the clutch fork Tap back the locking tabs and break the locking wire and remove the eight setscrews Detach the clutch nousing en M l sa s arere Jaguar Cars Limited 2005 Removal of Top Cover Remove the ten setscrews and lift off the lid Removal of Overdrive Overdrive Models Remove the six nuts securing the overdrive to the extension that is two nuts at each side and the two lowermost nuts of the four on the long studs Withdraw the overdrive Unscrew the seven setscrews securing the extension to the rear of the gearbox Withdraw the cam tap back the tab washer and unscrew the large nut Removal of Countershaft Remove the fibre plug from the front end of the counter shaft Drive out the countersha t from the front of the casing Important Ensure that the rear washer pegged o casing drops down in a clockwise direction looking from the rear to avoid trapping the washer with the reyerse g ar when driving the mainshaft forward see ill stration This is effected by rocking the gearbox casing and moving t
6. E TO THESE INSTRUCTIONS WILL RESULT IN THE GUARANTEE CLAIM BEING NULLIFTED Jaguar Cars Limited 2005
7. JAGUAR Number F 1 Section Gearbox and Overdrive Sheet 1 of 1 Date October 1961 GEARBOX CONSTANT PINION OIL SEAL Models affected 2 4 litre Mark 2 3 4 litre Mark 2 3 8 litre Mark 2 Commencing Gearbox Numbers GBN 55050 n a a UBM Type EB 868 On cars with the above gearbox numbers and onwards a flanged type constant pinion oil seal Part Number C 18739 is fitted to the recess in the clutch housing The interchangeabilityis_not affected but it should be noted that a chamfer of approximately 1 16 1 6 mm should be made on the edge of the recess to provide a lead in for the seal The oil seal should also be welt lubricated before pressing into the recess Spares Bulletin Number D 5 refers Amendment to Service Bulletin Numbers FF 3 and FF 4 Under commencing chassis numbers in the above bulletins insert the following R H Drive L H Drive 2 4 litre Mark 2 109308 126499 Jaguar Cars Limited 2005 JAGUAR Number F 2 Section Gearbox and Overdrive Sheet 1 of 1 Date April 1962 WARRANTY LAYCOCK OVERDRIVE UNIT Home Trade only If trouble is experienced with an overdrive unit during the period of warranty 12 months the unit should on no account be dismantied as the manufacturers are consequently unable to test and examine the parts in their original condition Only external checks such as valve setting and hydraulic pressure testing should therefore be undertaken
8. f 1 Date March 1964 GEARBOX NEEDLE ROLLERS All models The needle rollers on which the countershaft and 2nd and 3rd speed gears rotate are now graded according to their diameter and rollers of one grade only must be used in individual gear assemblies The part numbers of the individual grades are as follows Part No Description No off 0001 C 918 1 Needle Roller on Countershaft 3 mm 7 9000 58 7 0000 GC 918 2 Needle Roller om Countershaft 3 mm 0001 58 0001 C C 918 3 Needle Roll r on Counter hafit 3 mm 0002 58 C 1850 1 Needle Roller in 2nd nd 5rd Speed Gears 82 3 5 0001 somm 0000 C 1850 2 Needle Roller in 2nd and 3rd Speed Gears 82 3 5mm 0000 20001 C 1850 3 Needle Roller in 2nd and 3rd Speed Gears 82 3 5 0001 oo Spares Bulletin No D 15 refers Jaguar Cars Limited 2005 JAGUAR Number F 13 Section Gearbox and Overdrive Sheet of 2 Date September 1965 4 SPEED ALL SYNCHROMESH GEARBOX Service Bulletin F 9 refers to the 4 speed all synchro mesh gearbox as being optional extra on the 3 4 3 8 S Models This gearbox has now become standard equipment on all S models and also on the 2 4 3 4 and 3 8 Mark 2 models The chassis introduction numbers of the Mark 2 models are given below Model affected Commencing chassis numbers RzH Drivez LvHvDrivey 2g4 Lkitre Mark 2 119200 127822 plus 119149 to 119151 3 4 litre Mark 2 16934
9. ff the four retaining nuts This will expose the three plunger Springs which showta be removed together with the plunger and babis and shims ifr ny Withdraw the centre welCh washer at each end Of the top cover by piercing and prising aS necessary Then remove the Wired dowelL pins retaining the stop and the change speed fork on the centre striking rod so that this may be driven forward a sufficient amount to fit a washer 19 mm outside diameter and 4 12 7 mm inner diameter thickness1 16 1 6 mm onto the rod behind the change speed fork Ensure hat the washer clears the selectors on the other striking rods See illustration overleaf Replace the striking rod change speed fork and stop and refit the two dowel pins wiring them up as before Fit new welch washers either end of the top cover then replace the three balls plungers springs and shims if fitted in the respective holes Use a new gasket when replacing the selector housing and fit a new gasket on the gearbox case top face Place the gearbox in neutral offer up the top cover noting that it is located by two dowels and secure in position with the ten setscrews and spring washers two long screws at rear and two short screws at front Replace the tunnel cover and trim Jaguar Cars Limited 2005 m i rege iam zp Vim i HH tif j LLM M Jaguar Cars Limited 2005 JAGUAR Number F 8 Section Gearbox and Overdrive Sheet 1 o
10. he reverse lever backwards and forwards Removal of Constant Pinion Shaft With the aid of two tyre levers ease the constant pinion shaft forward until it can be withdrawn Removal of Mainshaft Tap the mainshaft through the rear bearing ensuring that the reverse gear is kept tight against the first gear After removal of the rear bearing from the casing fit a hose clip to the mainshaft to prevent the reverse gear from sliding off Slacken the reverse lever bolt until the lever can be moved to the rear Lift out the mainshaft forward and upward Lift out the countershaft gear unit and collect the needle bearings Joont A ewa Jaguar Cars Limited 2005 Service Bulletin No F 13 continued Sheet 2 of 2 Withdraw the reverse idler shaft and lift out the gear Reassembly Reassembly is the reverse of the dismantling procedure but the following points should be noted 1 Attach the rear thrust washer to the casing with grease and retain in position with the countershaft Za Fit the needie rollers to the countershaft gear unit ee with grease 3 To mesh the countershaft gear unit with the mainshaft turn the gearbox upside down and enter the countershaft taking care not to displace the needle rollers When refitting the overdrive align the splines in the usuai way push the overdrive on as far as possibte and rotate the overdrive flange until the oil pump plunger engages the cam on the mainshaft
11. ust ring bearing and sunwheel Examine the clutch linings on the sliding member for Signs of excessive wear or charring If wear is apparent renew the clutch sliding member Jaguar Part No 10848 Laycock Part No 65920 and the thrust bearing Jaguar Part No C 5968 Laycock Part No 65024 The unit can now be re assembled by reversing the dismantling procedure Fit the new clutch return springs contained in the modification kit and painted red on the end coil Unscrew the main operating valve plug located on the bottom of the unit on the same side as the solenoid Remove the spring piunger and balT Remove th operating valve by inserting a piece of stiff wire in the central bore and withdrawing downwards Insert the new valve contained in the kit ensuring that the hemispherical end engages on the flat of the small operating lever on the operating shaft Refit the ball plunger end spring kefit the plug and tighten fully ensure when fitting that the copper washer is correctly located Check the solenoid setting as detailed on Page F 25 of the 3 4 3 8 S model Service Manual Page F 28 of the 4 2 Mark 10 Service Manual and Page F 31 of the Mark 2 Service Manual Invert the unit and withdraw the accumulator spring plug Care must be taken not to lose any packing washers which may be fitted between the spring and the plug Place the packing washer 11304 62023 contained in the modification kit in the base of
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