my 98 xj8l has 98k on it The front drum is cracked I can still drive it if I baby it through start from stop acceleration.But the transmission repair shops in Denver are scandalous.The first shop told me 4k for a rebuild and he didn't even look at it.The second guy looked up the transmission code opened it up and said yup it's cracked but he also wanted to replace parts that were still usable 3.5k was his asking price.Then I called ammco they only rebuild or replace.So how can I get the drum and the seals done for less than a thousand.Only god knows I would do it myself but I don't have the tools and I could just keep driving it in limp mode probably for another who knows how long.But I want my power back and it seems I may have to rebuild the entire tranny since I cannot find some one to do just the drum.does anyone have a suggestion on how to get a mechanic to do just the drum and reseal.?Or should I drive it in limp mode for a couple months burn it out then get the rebuild.I have made all the necessary adjustments for this car I love the smooth ride and put bilstein shocks tensioners high quality plugs edge synthetic oil complete brake and caliper service you name it.I believe I will get another 100k with proper maintenance.

 

Too bad you are so far away. I have just replaced the broken 'A' drum in a 1998 ZF 5HP24 with the upgraded unit from transpartstech on eBay (talk to Oliver).

I have 2 of these gearboxes and they are not hard to fix if just the Forward drum is damaged. Be sure to check the piston seals ('O'rings) in the drum as they get damaged when the piston pushes the clutchpack too far when the snap ring groove fails.

A good used box would be the cheapest way out but the drum might fail in that one too if the pressure regulator valve is faulty.

bob gauff

 

If I recall, the A drum failure is commonly due to a combination of poor drum design AND excessive pressure - requiring both drum replacement and valve body or pressure regulator modification/repair... so replacing just the drum may not correct the true cause, and may cause the drum to fail again in the future.

I went with a full rebuild (with replacement of several hard parts to upgraded units) from a shop that had a Jag specialist - $3,800 - expensive, but I now have peace of mind.

 

QuadManic
The ZF certified rebuilder here in CT also believes the higher pressures caused in the faulty valve body causes the froward drum to fail. The owner there replaced the main pressure regulator housing, the worn piston and the Sprag also called the Free Wheel. They rebuilt the Torque Converter and replaced the Forward Drum with the updated one.

Jim Lombardi

 

How many quarts of fluid did it take to refill it please?

 

Hi
I extracted the first 5 pages from the ZF5HP24 part manual. It shows 10.5 quarts capacity (about 9.9 liters).

There is also a step by step instructions on the method to fill the transmission with the fluid.

It has a nice diagram of the transmission showing the drain/fill plug location.

Here is the PDF file:

ZF 5HP24 transmission parts manual pages 1-5.pdf

Hope this helps

I just looked at the transmission capacity on ALLDATAdiy.com - it says 10.6 quarts (10.05 liters) - If you could get all of the fluid out of the transmission & torque converter than you would need to buy 11 quarts (11 - 1 liter bottles to make sure you have enough).

You probably will be able to drain maybe 7 or 8 liters of fluid out. I am only guessing. Some of the other members like motorcarman or Quadmanic or testpoint or Gus will have a better idea because of their experience.

For the lowest price on the ESSO AT fluid will be at your nearest volkswagen dealership. Part number G-052-162-A2 - $19 per 1 liter bottle.

Jim Lombardi

 

WOW! Thank you sir, very helpful

 

Hi Donzi
I edited my post - please review and note that I added what I think the number of 1 liter bottles you need to buy.

And now I am adding the following to this post:
I did an internet search with the volkswagon part number for the 1 liter AT fluid and found this internet site that is selling it for just $12.35 per 1 liter bottle with free shipping on (and over?) $65 orders.
Here is the link:
http://www.rmeuropean.com/Part-Numbe..._D18BD03A.aspx

They are in Colorado and they use Fedex ground.

Jim Lombardi

 

Hi, I am a new member and have a 2003 xj8.

Was the drum and other transmission problems solved in later models?

I have a very good transmission repair person, 50 years experience on anything from fire engines to Jags.

Is there any thing I should mention to him when I take my jag for transmission maintenance and fluid change?

thanks in advance for any advice
Gregg P.