I’m rebuilding the transmission in my 2004 Jaguar XKR. It is a 6hp26 transmission, a 6-speed.

i bought a newer 6hp26 transmission from an 07 XK8 for parts.

As I am reassembling, I notice that my overdrive clutch is in two pieces where it should only be one. The separation looks too clean to be a break, but maybe it is?

Any advice on this?

 

That is one clean break. I am pretty sure it's not meant to be like that but someone else with more knowledge will chime in.

 

Makes me glad I have the Mercedes transmission in my car (2002 XKR).

Z

 

Interesting. I wonder if the splined portion was originally rotary friction-welded onto the rest of the shaft. I'm curious to check back and see if we have some machinists/metallurgy experts chime in.

 

I can't say why it broke, but that's definitely not right. The shaft should look like the one on the left.

 

My guess is that there was a defect in the metal of the shaft.

 

Curious, what prompted you to do a transmission rebuild and find this nightmare? What symptoms was your transmission displaying?

 

I'll try to keep a long story short. I buy the car on Ebay Feb 2021. It arrives around midnight, I take it for a drive and It starts having a fault code for transmission so I take it home. I notice a fluid leak when I park back at my house. Transmission pan was gashed during the unloading and I tried to refill with fluid but damage was already done.

Seller and shipper both help buy new pan when that didn't work they put in on a used transmission. Several repair attempts and transmission pumps later, I realize torque converter was to blame.

While the transmission was out I did the Sonnax zip kit, and the other wearable parts. I replaced a stator bushing.

Now I go to put it back together and questioned why my overdrive intermediate shaft is two piece when I only see it comes as one piece.

So I now know that it sheared, very cleanly, and needs to be replaced. Incidentally, the planetary gear housing can come in 29 tooth or 30 tooth splines and this is what the intermediate shaft fits into so I swapped the planetary gear assembly to use the intermediate shaft from an 07 XKR transmission. It seems like it will be a stronger unit being 30 tooth and splined diameter of 24.34mm vs the old shaft with 29 teeth and 23.45 splined diameter.

I hope this helps someone else! It's been a long journey! Just waiting on new e-clutch packs, ordered the Raybestos RTK-6R85 fricton disc pack.