At last, I've found the official ZF transmission catalogues from ZF.

ZF Transmission Catalogs

They're listing many of their transmission catalogs on the same page.

MG

Update on parts...

This is a quote from Automaticchoice.com

Drum: 1058 271 041 £65.98
O-Ring: 0734 313 151 £1.38
Bearing: 1058 202 016 £5.46
Rear flange seal: 0734 319 588 £6.66
Left flange seal: 0734 319 419 £11.95
Right flange seal: 0734 310 342 £15.82
Bolt cover caps: 0501 314 585 x 2 £2.52
Sump gasket: 1058 303 015 £13.75

I have had another quote from another supplier which is similar but they actually checked ZF Uk for availability and uncovered the fact that the drum is currently unavailable :-(

I've spoken to ZF UK as well and they have confirmed (it took a lot of pleading to get them to talk to me at all!) that the drum is currently unavailable as ZF Germany are looking at a new supplier for this part. Not good.

Chester Transmissions are looking into their stock pile to see if they have a good second hand one.

MG

Good news,

Chester Transmissions have enough gearboxes there to strip down for parts and they're going to find me a good secondhand drum.

Everything else will be new.

Fingers crossed I'll have a price this time tomorrow and I can start putting it back together next week in the evenings and maybe put the gearbox back in next weekend.

MG

wow good stuff - so about £125 for the parts.
Great thread thanks - looking forwards to more as it happens +++

Fantastic post!!! thanks for taking the time to take so many pictures.
I'm amazed that its so cheap to fix (except for the unavailable drum).
+++

Great news... I have parts :mexicanwave:

Chester Transmissions stripped down a Jag gearbox, checked over the drum (for any signs of damage and to compare with one from an Audi ZF) and gave me the thumbs up.

£102.60 all in including Special Delivery :D

http://i690.photobucket.com/albums/v...a/IMAG0455.jpg

Right... time to get it back together and running!

All I need now is lots of time, some oil and a sunny day!

Thank you to both Mark and Graham at Chester Transmissions

I'm hoping to get it back together this weekend coming.

MG

So the Jaguar ZF internals have a lot in common with the Audi ZF?

Our gearbox is a ZF 5HP24A.

The ZF 5HP24 shares many parts with ours and is fitted to many many cars!

ZF 5HP24 and ZF 5HP24A History


MG

I finally grabbed an evening to put the gearbox back together.

Here is where we left it last time. The complete troubled assembly.

http://i690.photobucket.com/albums/v...a/IMAG0479.jpg

Remove the circlip and lower the larger drum down.

http://i690.photobucket.com/albums/v...a/IMAG0480.jpg

Remove the top plate with circlip

http://i690.photobucket.com/albums/v...a/IMAG0481.jpg

And the damaged drum

http://i690.photobucket.com/albums/v...a/IMAG0482.jpg

New and Old next to each other. Note the extra ring sitting on top of the old drum. Explanation below.

http://i690.photobucket.com/albums/v...a/IMAG0483.jpg

When I spoke to Graham at Chester Transmissions last, he said that he was surprised that the bearing was running directly against the drum. I said that I was sure that it was.

As the new drum arrived, it was obvious that this drum had a bearing plate to protect the drum. This makes more sense.

So I went back to the original drum from my gearbox and sure enough, there is... or should I say was a bearing plate. I struggled to get it out of the drum as it has been worn so much (from both sides) that it was wafer thin where the bearing had been wearing. You can see that the metal actually broke away as I prized it up from the drum.

You can also see that the worn bearing plate has been turning against the drum and has ridged the drum. Either way, both parts (the bearing plate and the drum) are scrap.

http://i690.photobucket.com/albums/v...IMAG0486-1.jpg

New seals including THE O-ring!

http://i690.photobucket.com/albums/v...a/IMAG0488.jpg

New O-ring in place and lubricated.

http://i690.photobucket.com/albums/v...a/IMAG0489.jpg

New drum in place and bottom drum also raised into position. Chester Transmissions had pre greased the new bearing hence the blue grease.

http://i690.photobucket.com/albums/v...a/IMAG0490.jpg

Assembly complete ready for installation.

http://i690.photobucket.com/albums/v...IMAG0491-1.jpg

Gearbox ID plate for reference. You can see that ZF don't refer to it as a 5HP24A but just a 5HP24.

http://i690.photobucket.com/albums/v...a/IMAG0492.jpg

I turned the gearbox upside-down to check that everything was where it should be, that I had correctly aligned the selector into the valve block when it had gone back in etc. I need a bigger bench!

http://i690.photobucket.com/albums/v...a/IMAG0496.jpg

In order to get the repaired assembly back into the gearbox, you have align all of the clutch discs in the next clutch pack (inside the gearbox). You can only do this with the gearbox sitting vertically.

Excuse the muppet in the photo (me!). This was taken to give you an idea as to how big the gearbox is... not to put me on the map!

http://i690.photobucket.com/albums/v...a/IMAG0499.jpg

You can just make out the clutch discs here.

http://i690.photobucket.com/albums/v...a/IMAG0497.jpg

You need to align them to get the assembly back in.

I used two screw drivers to make it easy.

http://i690.photobucket.com/albums/v...a/IMAG0500.jpg

In!

http://i690.photobucket.com/albums/v...a/IMAG0501.jpg

Next is the bearing between the assembly and the intermediate plate which houses the oil pump. Sorry forgot the photo. It's obvious which way it goes in.

http://i690.photobucket.com/albums/v...a/IMAG0502.jpg

Tighten up the bolts (I checked that the shaft could still be turned easily while this went in).

http://i690.photobucket.com/albums/v...a/IMAG0503.jpg

These are M6 bolts, 7ftlbs (84 inch lbs on my small torque wrench)

New caps in.

http://i690.photobucket.com/albums/v...a/IMAG0504.jpg

Left output shaft tube refitted.

http://i690.photobucket.com/albums/v...a/IMAG0505.jpg

This pushes back in easily.

http://i690.photobucket.com/albums/v...a/IMAG0506.jpg

Turning to the other side, the diff went back in and before I put the sideplate on, I replaced the output shaft seal.

http://i690.photobucket.com/albums/v...a/IMAG0507.jpg

These bolts are M8s so 18 ftlbs in the normal even spread sequence. The output shaft is also an M8 so 18ftlbs again.

Turning to the other output shaft. I wanted to change the seal on this as well. There are signs of having leaked but not much (more of a damp patch than oil running down) so I tried to pull the shaft out of the bearing.

http://i690.photobucket.com/albums/v...a/IMAG0508.jpg

Here you can see the circlip.

http://i690.photobucket.com/albums/v...a/IMAG0509.jpg

Despite some heat (having removed the sealing ring first) it wasn't having any of it and I don't have a press here. It's in my other workshop some 160 miles away! Ho-hum. It'll have to wait until another time.

I bolted it back in, again M8s at 18 ftlbs.

Turning to the sump, one new gasket, some sealant and it was back on.

http://i690.photobucket.com/albums/v...a/IMAG0510.jpg

M6 bolts so 7ftlbs again.

The last job to do was change the rear output shaft seal.

Loosen the centre bolt

http://i690.photobucket.com/albums/v...a/IMAG0511.jpg

This has been leaking lots for a while!

http://i690.photobucket.com/albums/v...a/IMAG0512.jpg

Old seal out

http://i690.photobucket.com/albums/v...a/IMAG0513.jpg

New seal in

http://i690.photobucket.com/albums/v...a/IMAG0514.jpg

Flange back in and bolted up to 18ftlbs (M8 again).

And that's it.

I'll be putting the gearbox back in the car tomorrow so we'll see how it goes. I'll put up an update when I get a chance.

MG

Stunning work, and brilliantly documented.... thanks for posting

Cant wait to see how she performs... +++


You do realise you're going to have an eager queue of D2 owners with broken gearboxes hunting you down soon dont you... ;)