Modern Nightmares

dmcsweeney

Active Member
Hi all,

While I do believe modern cars have come along way in terms of reliability, I quickly learning what a pain in the a** they can be when they go wrong. I'm just home from a nightmare evening in the workshop with my every day car, a Jag X-type diesel. It all started 2 weeks ago, on Friday evening as I rushed back from work to try and get my white P6 ready for a show. I spent a few days fretting about getting the Rover ready as it hadn't had a long run in 2 years, and had probably only covered about 10 miles in the last 12 months due to work commitments. I left work and had difficulty changing down at the first junction. It got progressively worse so I pulled over and checked the clutch fluid and gear selector cables. I drove on, and as I climbed a hill I decided to change down and see what happened. Bang :cry: . I rolled onto the narrow hard shoulder, no drive in any gear, just a horrible grating noise. It was too dangerous to root around too much so I called the AA. The patrol man arrived and stuck it in gear as I watched. It looked like the nearside CV had broken (a common X-type issue, and I'd noticed play in the shaft at the last service) so they recovered it to the workshop. I stripped the whole front end down, including dropping the sub frame and replaced both drives (both well shot), anti roll bar bushes and both front wishbones. While it was down I decided I'd re bush the rear end as well. I fitted the front wheels so I could move the jacking beam to the rear, only to find that I could rotate the wheels with the car in gear, accompanied by a horrible tearing sound. Fitted the wheels, tried every gear, lots of noise, no drive. Bye bye gearbox :cry: . The last time I had the box out it took me a few days, involving taking half the car apart, I feel like crying. Why can't it be as easy as a P6 box swap??

BTW the P6 didn't miss a beat all the way to the show and back, and has continued to run like a dream since :roll: .

Rant over :twisted: .

Regards,
Dave
 
Apparently thats what happens when the clutch/flywheel assembly fails!
Neighbours went and cost him close to £1000 to have fixed.
 
Dmf. Buy a mondeo one and replace the starter or you'll end up doing it again. Dad got his done for 600.
 
Dual Mass Flywheels, don't you love 'em :( Replacing it with a conventional type will solve the problem, but it will knock eight bells out of the gearbox due to the extra vibrations being transmitted.
 
DMF failure doesn't normally involve sudden total loss of drive , normally juddering noise and vibration
If it had been a CV joint you wouldn't have had trouble getting into gear so it looks like misdiagnosis by the AA man
 
Hi all,

Definitely not a DMF failure, as this is what lives in there at the moment

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Old and new

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It's basically a transit valeo solid flywheel with 6 teeth for the crank sensor ground down to suit the jag. It's fitted with a heavy duty national transit 125 TDCi clutch. Unless the centre of the driven plate has parted company I think it is definitely the box. All the noises seem to be coming from the box, and the nearside drive can be moved up and down. Not good :cry: . Luckily when the original DMF started to give out 4 years ago I managed to save the starter by blowing the dust out with an air line. I think the solid flywheel probably has shortened the life of the box a bit, along with the tuning box which can shove about 380NM (up from the original 330NM) at 1900RPM through the drive line!! I've also read that badly worn drives (a common problem, and mine were well shot) can move and cause the diff gears to feast on themselves on Mondeos with the same box. I've sourced a 60k box for €150 + €30 delivery, plus I've ordered a replacement rear crank seal as it was leaking. I'll assess the clutch and make a decision on replacing it or not. Also, in fairness to the AA man, where I chose to break it wasn't the best place to diagnose problems! In their defence they towed me to well outside my coverage area FOC and slid the tilt and slide onto the front of the lift and dropped the car straight on. Saved humping 1600kgs about!

One thing I didn't want to repeat this time was all the hardship of trying to support the engine, and drop the box out with ropes, jacks and timber like last time. I could barely get under the lift with all the props, so I splashed out on some new toys, an engine support beam and a transmission jack. The jack will also come in handy for getting the LT 77 back in the Almond P6.

I'll let you know what falls out when I open the box!

Regards,
Dave
 
Back from the workshop, the box is now on the ground and definitely dead :( . I stuck the old drives on and rotated them in each gear, the input shaft turned, but when I held it with my hand it stopped turning and I can feel metal on metal contact in the box. Must say I'm impressed with my new toys though (transmission jack and engine beam) as they made the job far easier, wish I'd bought them years ago.

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What a fun day :twisted: .

Regards,
Dave
 
I'm thinking that it is fortunate that my lack of proper equipment keeps me from attempting what you have gotten yourself into !!
 
Is this a "sealed for life " gearbox ? Some you cannot top up as there is no level plug so you have to drain and refill with a measured amount . Who would bother (except me) ?
 
DaveHerns said:
Is this a "sealed for life " gearbox ? Some you cannot top up as there is no level plug so you have to drain and refill with a measured amount . Who would bother (except me) ?

Good on you for doing things properly, and as a little reward for you endeavours, in future drain off the old oil, refill with the correct measured amount, and then before using it, make yourself a dipstick to fit in the filler hole (welding rod is good) and then make a saw mark on the dipstick at the fluid level. Then in future just top up to the mark.
 
Right, now time for me to eat yet more humble pie. Half asleep when I had the box on the ground I had only one drive pushed all the way in :oops: . Needless to say, when I fitted the second one properly (using the 2 old shafts) it turns out the box was ok. Now, in my defence I did check it properly on the lift, and I definitely had no drive. I pulled the clutch off and found the driven plate centre (with the splines) had broken away. Now I am silly for buying a box before removing the old one, but all is not lost as the diff is a bit slack and rattled at low speed for the last few years.

The video says it all http://www.youtube.com/watch?v=LKFpRQfo ... ata_player.

Ps, while there is no mention of changing oil in this box there is a drain and filler plug, and the oil has to be removed when the drives are removed from the box.

Regards,
Dave
 
Now I am silly for buying a box before removing the old one

If you're anything like me you want all the bits there to fix the car before you start taking it apart... i certainly rely on the car and cant be without it for long periods of time!

Rich
 
WarrenL said:
What mileage has the X-type done to suffer such a catastrophic failure?

178,000 miles, which certainly isn't excessive. I managed 175k in my old sierra, regularly towing trailers, without clutch issues. But then again, that had no torque.

suffolkpete said:
I suspect this illustrates my previous point about not replacing a DMF with a conventional type.

To be honest, when I replace the car next year (with another X-type) I'll be sticking with OEM DMFs if I have a failure. The more I hear about conversions, the less I want to fit another. Luckily my mileage is now a fraction of what it used to be (down from a peak of 35k per year) so hopefully I'll be doing less of this! On the plus side, I was terrified of FWD clutches swaps until I tackled this car, so I have learned a lot :roll: . I've got removal down from over a day to 5 1/2 hours!
Regards,
Dave
 
rockdemon said:
My dad's x type is on 250k from memory...

Is it petrol or diesel?

rockdemon said:
Now I am silly for buying a box before removing the old one

If you're anything like me you want all the bits there to fix the car before you start taking it apart... i certainly rely on the car and cant be without it for long periods of time!

Rich

I'm glad I'm not the only one.
 
diesel... Had 2 dmfs so far though! It's a 55 plate. He bought it on 120k for just over 3 grand at 3 years old
 
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