I'm in the middle of a pan/filter/fluid change on my '03 XK8 (viewed Rev's video). All went well but just broke a new 8mm (6 pt) combo wrench trying to unscrew fill plug (yes, I was turning it in the correct direction). I used an extender bar to apply more leverage to the tiny wrench when the wrench head snapped. Haven't put the new pan on yet so I can see the interior part of the plug. Soaked it in penetrant but am now at work out of town, so continuing next week. All components exceptionally clean and free of corrosion. Any suggestions on alternative tool? Perhaps a heavier-duty, long handle 8mm wrench? Any suggestions appreciated.

 

Are you saying there is a 8mm external head on the plug? The ones I have seen use a hex key (allen type) which will work with a piece of pipe as an extension. A couple of people have asked about the procedure and I always suggest breaking the plug loose while the transmission is hot and before draining. Obviously, it's too late for that now, but you may be able to heat the area with a propane torch.

 

Some members here have had success breaking that ZF fill plug free by inserting a cut-off piece of an 8mm Allen wrench into the fill plug, then attaching two identical 8mm box wrenches lined up side-by-side on the Allen wrench piece, then repeatedly striking the two box wrenches with a big hammer. You use two wrenches because using just one wrench apparently increases the chances of that wrench bending rather than loosening the fill plug....

 

RJ - yes, I'm using an 8mm hex key with a drive socket attached to the back (unusable due to lack of space).

 

Jon89 - thanks for the double-wrench suggestion. That will increase the area that force is applied to on the hex socket along with an increase in stiffness in the lever action. I'm also planning to use a freeze-penetrant spray along with a little light hammer persuasion to coax the plug into moving. I'll let you know how it went.

 

Jon - by the way, my airline is moving me to RDU June 1 and I will bring my XK8 from Cincinnati - I'll use it for my daily driver there (though I will air-commute home to Cincinnati). My question... anything Jag-interesting that goes on in the RDU area?
Thanks,
Bart

 

Yeah i bent mine as well...... and in hindsight would recommend making sure all bolts are free as the very 1st thing to do. I managed if I remember correctly to get a socket and extender bars with a knuckle. I kinda mixed and matched and just ( and I mean just ) get the socket over the plug. Believe the ratchet was just tight against exhaust. But did do it and just broke plug free. Then used the little thumb wrench. Just a note when I filled and ran the car up to temp until fluid dribbles out (as per instructions ) I used my hand and reached in and screwed the plug on enough to stop dribble. If you are careful you will not burn your hand. When car cooled i tightened and used the knuckle extension bar arrangement to tighten. ( 99 xk8 )
Good luck !!!!

 

Also if you get a professional quality 8mm Allen wrench (such as MAC or SK, which can be ordered from their websites) it will not break or twist on you.

 

Bart,

I live about ten minutes from RDU and hike in Umstead State Park (adjacent to RDU) with one of my dogs most weekday mornings as soon as the rangers unlock the gates around 6:45 to 7:00 am....

There are a few jaguarforums.com members living in this area, and I know there's a local Jaguar club but I'm not sure how large or active it is. The annual Raleigh British Car Show took place this past Saturday but I didn't attend due to the heavy rains that nailed us off and on most of the day. Had much better weather for last year's show and it was a lot of fun....

My cousin is a pilot for Southwest out of the St. Augustine, Florida area....

Good luck with your relocation. I think you'll enjoy the area....

 

Thanks, Steve-
yeah, I'm glad I broke a Craftsman... guaranteed. I'll replace it and get a second one and see if that does the trick. For future use I will see about the tool brands you suggested.
Bart

 

Update on my trans fluid change...
The double-wrench scheme didn't work for me because the was not enough length between my socket hex to accommodate the both wrench heads plus drive the hex key all the way into the drain plug. Anyway, I ended up breaking another Craftsman 8mm 6-point, then finally broke the plug loose with another 12-point wrench. Yay! After that, the adventure of correctly filling the trans went fairly well and I only burned myself a little. The car took about 7 quarts of Mercon SP, which was about a quart more than what I drained out of it. The car does shift noticeably smoother, although it is still a bit clunky when it goes into overdrive. I'm happy with the job and thank all who provided resources on the forum.

 

How clean (or nasty) was your factory-fill of Lifeguard 6 ATF? When new, it's a relatively clear golden-colored....

 

Jon - sorry for the late reply - the color of the fluid I drained was caramel colored. I thought it was relatively "clean" and there were no metal filings on the magnets on the oil pan/filter. I now suspect the transmission had been serviced at least once prior to my purchasing the car... all the pan bolts were of the upgraded T-40 torx variety and came out easily; I still suspect it was not properly filled at that time since I drained less than what I ended adding. The car is shifting much smoother and there is no more "whoop" on big downshifts. Keeping my fingers crossed! Now trying to do some research on why the locking servos for the door-locks are all of a sudden not working!

 

Sounds like you brought the fluid level up to where it should be. I hope that eventually solves all of your issues. Keep us posted....