Transmission, clutch, overdrive, propeller shaft, rear axle, differential
The gearbox selector (shifter) protrudes through the tunnel gearbox cover, and is finished by a rubber grommet and ring (which screws into the fiberglass tunnel cover and holds the grommet in place). Four small holes were punched in the grommet; the ring was sanded and then spray painted with faux......
In preparation for testing the starter motor (before the engine is put back in the car), the engine and gearbox were filled with oil — Brad Penn 20W-50 partial synthetic racing oil for the engine, and Lucas 80W-90 gear oil for the gearbox and overdrive unit. The listed capacities are......
After the engine was installed, a routine check highlighted a bad problem … the crankshaft did not fully rotate. Worse, there was an unsettling “clunk” of metal-on-metal when the crankshaft was turned in either direction after a few degrees of rotation. (Of course, this problem should have been caught before......
Without the front suspension, installing the engine from under the chassis is a safe and relatively anxiety-free method with a four-post lift. First, the alternator and oil filter are removed; the intake and exhaust manifolds were not yet attached. Next, the engine/gearbox is moved with an engine hoist to marks......
The 2.4 engine doesn’t have a convenient hook for lifting, so a sling harness was used to remove the engine, and then separate it from the gearbox. As they say, assembly is the reverse of disassembly. The engine sling is first lifted a few inches so the engine stand back......
See also overview of the gearbox-overdrive restoration. The clutch slave cylinder should have an external spring to help bring the release bearing mechanism back to its starting (that is, clutch engaged) position. These somewhat delicate springs tend not to survive well, and ours didn’t. The spring attaches to a small......
Back in December 2014 we assessed the gearbox-overdrive unit, and now it’s time to do the restoration work. The gears worked fine prior to disassembly in June 2014, so the internal mechanisms will be left untouched. There was so much grime that the integrity of the seals couldn’t be determined......
During our test drives before disassembly, the gearbox and overdrive seemed to work fine. The main gearbox/overdrive defect is annoying oil leaks, a familiar Jaguar issue. A secondary concern is the aging electrical system, including the overdrive solenoid, switches, and wiring. Our plan is to do a cosmetic restoration of......
The left thread on the rear axle, which looks undamaged, was 30 thousands of an inch (0.03″) too high! This could have been caused by heat stress or compression force when we pulled the rear hubs. The castle nut just refused to go on. Bruce suggested running a die along......
The Jaguar 2.4 model with overdrive had two differential options, a Thornton Powr-Lok or a conventional one. There is no way to tell these apart from their outside appearance so Jaguar appended a small metal ID tag. The Thornton Powr-Lok unit was indicated by a BP-L code (for “British Powr-Lok”).......
