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2004 XJR (x350) with 105,000 miles
Good evening. While replacing my fuel filter and enjoying a cigar this past weekend, I noticed that a dark liquid had accumulated on the bracket aft of the transmission, which is shown in the attached photo. The areas around the edges of the pan itself appear clean. I did some research, and it appears that the fluid may be coming from the cylindrical “mechatronic sealing sleeve,” (FCP Euro# ZF 24647588725) which tends to fail and leak. I also came across a video of this part being replaced on a BMW.
In performing said research on this site, I came across “ZF Parts Service Information Oil Change Kit for Automatic Transmissions” that someone had been kind enough to post. Thank you. Replacing the transmission fluid is on my to-do list. So, this seems like an ideal time to take on this project. Per FCP Euro, the pan/gasket/plug are part# ZF 24152333903; the bolts are ZF 24159896928; and the fluid (Lifeguard 6) is part# ZF S671090255.
I have several questions about the process. The first two are really threshold questions for the remaining questions. I appreciate any insight. Thank you!
1. Is the leak consistent with a leaking mechatronic sleeve?
2. If so, is this something that can be done without removing the pan and the mechatronics unit? The reason I ask is that I read in another thread that changing the transmission fluid should only be done by a professional due to the temperatures that have to be monitored. Is this correct, or is this something you can do with an OBDII tool or laser thermometer? If I need to take it into the shop, I will.
3. As far as gaining access to the transmission, I only have two (2) ramps. The transmission pan itself is eminently accessible. However, the space above the bracket appears pretty tight. Is replacing the sleeve something that can be accomplished using ramps alone?
4. The ZF directions state that the car should be “horizontal.” Is the angle created by the ramps (7” – equaling an incline of under 4 degrees) sufficient to cause problems, e.g., result in an improper fill level?
5. The ZF directions mention taking the temperature of the transmission fluid at various stages during the process. I assume that there is an OBDII sensor that does this and that such sensor can be used via OBDII Whiz, yes?
6. The ZF directions state that if the transmission is overfilled, to wait until it gets to 40C/104F but under no circumstances let it get to 50C/122F. It sounds like there is a method for excess fluid to automatically drain but that there is a risk of the escaping fluid igniting upon contact with the exhaust components. What is being accomplished here with waiting until its hits 40C? What is the risk here of it reach 50C?
7. The ZF directions state to “Select R and D position. Shift to 3rd gear” and to “hold each gear for approximately 3 seconds.” I assume this means put it in reverse for 3 seconds, put it in drive for 3 seconds, and put it in 3rd for 3 seconds, correct?
8. On a few occasions (not often) while driving on the highway, I get a “transmission fault” notification. When this happens, the car is stuck in one gear. Normal operation can be reestablished by turning the car off and turning it back on again. Is this something that could be related to the leak? Other than is, the car drives perfectly.
9.Assuming that I move forward with replacing the transmission fluid and, hopefully, replacing the mechatronics sleeve, are there any complimentary projects that I should take on while I have the pan off? In the video, the guy replaces four (4) cylindrical sleeves where the mechatronic unit mates with the transmission as well as another rectangular "gromet" on the mechatronic unit itself.
Answer to 2: No, you need to remove the pan and the mechatronic itself. You can monitor the temperatures with eithed SDD, or with a laser thermometer.
Answer to 3: I think that it could be done, as the sleeve itself needs to be removed from within the transmission housing, but having the use of a lift would definitely make things easier. For refilling the transmission the car needs to be level.
Answer to 4: yes, the angle will create problems. See my answer to 3...
Answer to 5: I do not know whether a generic OBD reader can see the values of the sensors, you will probably at least need a Jaguar specific code reader, or, better yet, SDD.
Answer to 6: transmission fuid expands a lot with temeprature, that's why it is necessary to check the level at temperatures below 50C, otherwise the level will not be correct. Tere is no automatic drain, but too much fluid will exit the transmission frm the filling plug hole if the temperature is too high, thus bringing the oil level of the transmission to a level that will be too low.
BZW, do not switch off the engine while the filling plug is off! If you do that, a lot of the fluid will gush out of the transmission filling hole.
Answer to 7: it means to put the transmission into all positions available, down to 2nd, and hold it for 3 sec in each position.
Answer to 8: it could be, but to have a better picture you need to see whether there are any fault codes (or DTCs, as they are called by Jaguar). For that, you will read a Jaguar specific code reader.
Answer to 9: yes, the recommendation is to replace those, as well, as they are made of rubber. There is a complete kit from ZF that includes them. Apart from this, nothing comes to my mind.
Answer to 2: No, you need to remove the pan and the mechatronic itself. You can monitor the temperatures with eithed SDD, or with a laser thermometer.
Answer to 3: I think that it could be done, as the sleeve itself needs to be removed from within the transmission housing, but having the use of a lift would definitely make things easier. For refilling the transmission the car needs to be level.
Answer to 4: yes, the angle will create problems. See my answer to 3...
Answer to 5: I do not know whether a generic OBD reader can see the values of the sensors, you will probably at least need a Jaguar specific code reader, or, better yet, SDD.
Answer to 6: transmission fuid expands a lot with temeprature, that's why it is necessary to check the level at temperatures below 50C, otherwise the level will not be correct. Tere is no automatic drain, but too much fluid will exit the transmission frm the filling plug hole if the temperature is too high, thus bringing the oil level of the transmission to a level that will be too low.
BZW, do not switch off the engine while the filling plug is off! If you do that, a lot of the fluid will gush out of the transmission filling hole.
Answer to 7: it means to put the transmission into all positions available, down to 2nd, and hold it for 3 sec in each position.
Answer to 8: it could be, but to have a better picture you need to see whether there are any fault codes (or DTCs, as they are called by Jaguar). For that, you will read a Jaguar specific code reader.
Answer to 9: yes, the recommendation is to replace those, as well, as they are made of rubber. There is a complete kit from ZF that includes them. Apart from this, nothing comes to my mind.
Best regards,
Thomas
Thomas, thank you so much for your answer. It is phenomenal! I looked and was able to find the kit of seals. I will look this weekend to see if my OBDWhiz will read the temperature. If it can, I may get an additional set of ramps or use Jack stands to level the car. Thank you again!
Thomas has answered your questions well and I can only think of a few additional things to mention:
The reason the fluid pan must be removed to change the electrical connector sleeve is because the sleeve locking handle is inside the pan.
Note that there are two different bridge seal designs, one that fits the BMW version of the transmissions, and one that fits the Jaguar version. This is the rectangular rubber seal that fits between the valve body and transmission, along with the cylindrical seals. If you order your parts from FCP Euro or California Transmission Supply Company (thectsc.com), you should receive the correct part.
In the past, we have been able to use Ford Motorcraft Mercon SP, which was the same fluid as Lifeguard 6 but at half the cost. In mid-2023, Ford announced that Mercon SP had been discontinued and Ford then recommended Mercon LV for use in the Ford versions of the 6HP transmissions. However, reports on some of the Ford forums indicate that dealerships found that LV did not work properly in 6HP-type transmissions, so do your own research before considering Mercon LV. You may still be able to find some Mercon SP, but prices have gone up. If you can find Lifeguard 6, it's the safest choice.
Note that the transmission filter is molded into the pan, so the entire pan must be replaced. The "genuine ZF" pans are made by IBS Filtran GmbH. You can sometimes save money on an IBS pan that is not marked ZF.
The original steel pan screws tend to galvanically corrode to the threads in the aluminum transmission and either the Torx socket in the screw head will strip or the screw will break during attempts at removal. Cleaning the ends of all screws that protrude up above the transmission lip with a small wire brush and applying a good penetrant (not WD40) can help. Also, buy a set of new, upgraded screws that use a larger Torx bit and are far less likely to strip.
If your OBDII scan tool can read Live Data, it is very likely that it can read the signal from the Transmission Fluid Temperature Sensor. If not, and you use an infrared thermometer, be sure to aim its beam at the fluid dripping from the transmission fill hole and not the pan. The pan is plastic and not a good conductor of heat, so its temperature will read significantly lower than the fluid and cause you to set the fluid at an incorrect level.
The highest correct fluid level is set at 30°C, the medium correct level is set at 40°C, and the lowest correct level is set at just below 50°C. Try to set the level at no warmer than 40°C, which is only 104°F, or just just above human body internal temperature.
Your "Transmission Fault" warning may very likely be related to transmission fluid leaking into the connector sleeve, contaminating the electrical connector pins, and interrupting electrical communication between the Transmission Control Module (Mechatronic, which is assembled with the valve body inside the transmission) and the Engine Control Module, DSC Module and others.
If the pan screws are stuck into the transmission. You can break the plastic oil pan off and then grab the screw head and remove with vice grips. Jaguar upgraded the pan bolts to a larger version and I would install these. A dab of anti-seize might be good too.
If you are looking for ZF stuff the CTSC is a real goldmine! The CTSC-ZF Parts
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2004 XJR - Leak aft of Transmission
