MG ROoveER GRouP @ | TECHNICAL BULLETIN [Woaerbervatve; eT se Rover 75 MG ZT automatic Date: 22.10.9008 Rover 45 KVE automatic Section: TRAISMSGCN Tie FLUID LEVEL CHECKING PROCEDURE ~ JATCO AUTOMATIC. Affected range: All vehicles with JATCO automatic transmissions. | Doseription: - ju | i Vilal that the process for checking the transmission ud level is understood end applied when either: + Fluid is replaced during service. + The ansmission hes been replaced + A transmission fault exists and fluid level figures are required for ciegnesis and prior consuitation purposes. + Unrelated repairs art ried out resuling in transmission id loss, .@. engine or dive shaft removal, Action required: Ensure that all technicians involved in repair and servicing are familiar with the dé bed process Detatl The following deseribe the procedures for drain and re-fil/ cher ing fluid REPLACING FLUID DURING SERVICE (repair number 44.24.02) Drain 2 WARNING: Observe due care when draining gearbox fluid as the fluid can be very hot. 41. Position the vehiole on ramp. jorake and position chosks under front and rect dorbally panel, Position CLEAN container under gearbox: Clesn area around drain pl Remove gearbox drain plug and discard sealing w Allow fluid to drain into container. IMPORTANT: DO NOT DISPOSE OF DRAINED FLUID 8 Cloan drain plug and ft new scaling washer. ._Fitdrain glug and tighten to 45 Nm. ICAL BLILLETHN- Ta 1 Croup Ud 2002Refill 10, Clean area around filer plug and remove plug, (on Rover 7S/MGZT petrol versions, first remove ait | cloanor assembly for access), 11, Measure the quantity of praviously drained fluid, then add the equivalent quantiy of fresh transmission ‘luid plus en additonal! itve, Ensure fluid is to the correct specification, Le, Texaco N4O2, 12, Clean and refit uid filer plug, 13, Connect T4/TestBoak to vehicle to measure gearbox ful temperaiwe, 14, Position container under gearvox. 18, Start engine and allow to ide. 16, To cliculate the fluid sufficiently, APPLY FOOTBRAKE and move selector lever from 'P*through all gear positions, pausing in each gear position for 2-3 seconds and return to 'P’ position. Observe fd temperature, & should not exceed 20° C al this stage, 17, Allow to ide further until Muid temperature (2s read on Te IMPORTANT: ff fluid temperature is allowed to exceed 400 C during warm-up, the level reading taken will be Inaccurate and the vehicle will have to stand until temperature eventually drops. (this ean take several hours) ‘estBook) reaches 350 C 18, With the engine atl eunring, clean area around fluid level plug (underside of gearbox ~ eee illustration} and remove plug using 2 Smim Allen socket, alow any excess Tid to drain off. Discard sealing washer. 10. Alle excess fluid to completely crain, .. walt until drins stop or temperature reaches 40° C. Ifo fluid loss was apparent when level plug was removed, add adcitional fuid until it starts to run from the level plug aperture. NOTE: adding additional id may have caused fuid temperature to drop, allow temperature to exceed 36° C then wait until ps stop or temperature eventually reaches 40° C. IMPORTANT: If temperature is allowed to exceed 40° C during draining, the fluid remaining in the gearbox will expand and continue to drip, this will result in en under fill condition, 20. Refit filer plug. 21. Fit new sealing washer to level plug, fit and tighten level plug to 15Nm. 22, Stop engine. 23, Disconnect T4/TesiBook. 24, Lower vehicle. 25, Refit ai cleaner assembly where applicable. Neus Page 2osADDING FLUID FOLLOWING GEARBOX REPLACEMENT AX WARNING: Observe due care when draining gearbox fluid asthe fluid can be very hot. Fill Procedure 4. Clean area around filer plug and remove plug, (on Rover 75/MGZT petrol versions, first remove air Cleaner assembly (or access). 2, Add 1 lire of the correct Specification transmission fluid, Le. Texaco N02. 3. Clean and reft uid ler plug. 4, Connect Ta/TestBouk to vehicle to measure gearbox fluid temperature, 5. Postion container uncer gearbox, 6. Stan engine and allow to idle 7 To circulate the fluid suficiently, APPLY FOOTBRAKE and move selector lever from‘ through all gear positions, pausing in each gear posiicn for 2-2 eaconds and return to 'P' postion. Observe fuid temperature, it should not exceed 30°C at this siage. 8 Allow to idle further until uid temperature (as read on T4/TastBook) reaches 35° C. IMPORTANT: If fluid temperature is allowed to exceed 40° C during warm-up, the level reading taken will be inaccurate and the vehicle will have to stand until temperature eventually drops: (this can take several hours) 2. With the engine stil running, clean area arcund fluid level plug (underside of gearbox - see illustration) and remove plug using a Sirim Allen socket, allow any excess fluid to drain off. Discard sealing washer, 10. Allow ex288 fluid to completely drain, e. wait until drips stop or temperature reaches 40° C. Ino fluid Joes was apparont whon lovel plug was removed, add additional fluid until it starts (0 run from the lave! plug aperture. NOTE, adding adaltional fuid may have caused Suid tempereture 10 droo, allow fomperature to exceed 35° C then wait until drive stop or tomporature oventualy reaches 4 C. IMPORTANT: If tomporature is allowed to excoed 40° C during draining, the fluid remaining in the gearbox will expand and continue to drip, this will result in an uncer fill condition, 11. Refi filer plug 12. Filtnew sealing washer to level plua, fit and tighten level plug to 18m. 13. Stop engine. 14, Disconnect T4/TastBook. 45. Lower vahicle. 16, Refit air cleaner assembly where applicable, TECHNICAL BULLETIN TRADED ISSUE ¢ ENGUSH Page at 5 ShOR up Ud 2002CHECKING FLUID LEVEL FOR DIAGNOSTIC PURPOSES (and Prior Consultation) AX WARNING: Observe due care when draining gearbox fluid as the fluid can be very hot. Level Check Procedure Clean area around filar plug and remove plug, (on Rover 7SIMGZT potrol versions, frst remove air cleaner assembly for access). ‘Add execlly 1 lire of the correct specification vansmission fluid 2. Texeco N402 Clean and refit ud fle plug, Connect T4/TestB00k to vehicle to mezsure geerbox fluid temperature Ensure that gearbox temperature |s below 30° C, Postion GLEAN container uncer gearbox. Slat engine and allow to ice, To ciroulete the fluid sulticiently, APPLY FOOTBRAKE and move selector lever from "P’ through all gear positions, pausing in each gear postion for 2-3 coconds and rotumn ta’ position. Obsorvs fluid famperature, it sould not exceed 30° C at this stage. 9. Allow to idle further untd uid temperature (as read on T4/TestBook) reaches 36° C. IMPORTANT: If fluid tomporature is allowed to exceed 40° C during warm-up, the level reading taken will be inaccurate and the vehicle will have to stand until temperature eventually drops, (this ean take soveral hours). PaaoPeN ia a 410. With the engine stil running clean area around iuid level plua (underside of gearbox — see iustraton) ‘and remove plug using a Sri Allon socket, alow excess ‘uid to drain into the clean container. Discard sealing washer. IMPORTANT: DO NOT DISPOSE OF DRAINED FLUID - THIS IS REQUIRED LATER FOR LEVEL CALCULATION AND OBSERVATION OF FLUID CONDITION. 41, Allow oxcoss fd to completely drain, ie. wait uni dips stop o: temperature reachos 409 C. Ifno fuid loss was apparent winen level plug wes removed, add adkitional ful in 7 litre quantities unti fluid begins todrain. Allow excess Mid to completely drain into clean container. NOTE: adding adchtional fd may have caused fluc temperature to drop, allow temperature (0 exceed 35? C then vat until dns stop or temperature evenivaly reaches 4° C. IMPORTANT: If temperature is allowed to exceed 40° C during draining, the fluid remaining in ‘the gearbox will expand and continue to drip, this will result in inaccuracies when calculated. 42. Refi filer plug 13, Fitnew sealing weshter to level plug, fit and tighten level plug to 15Nm. 414, Stop engine. | TECHNICAL BULLETIN 150030 TESUET ENGLGH Pago tof ENG Rover Group Us 200245, Disconnect Té/TasiBook. 48. Lower vehicle 17. Refit air cleaner assembly where applicable. 18. Inspect the drained fluid concition and note any debris content, dscolouration or burnt odour 419. Follow the prior consultation process for adulifonal checks. 20. To calculate how much the transmission was ‘under filed’ prior to the check being carried cut, perform the following calculation: (Amoune drained) ~ (the amount over filed) = actual under fill amount (fluid low) Example: 200e¢ (drained) ~ 1000cc (overfilec) = - 800ce therefore the fuid level was low by 800ce The permissiote Nuid level tolerance is 4 30966 LEVEL CHECK EXAMPLE £35-40°C 200ce - 1000cc = - 800cc low ADDITION INFORMATION + ILis recommended thatthe level checking procedure Is canied out from cold, 2, after an overnight stand. Since normal gearbox opetaing temperature is approximately 60°C, it may take severe! hours for the temperature to drop below 30°C a0 that eccurate checking can proves. ‘+ New transmission assemblies are supplied partially filed with fui, this is due to the unit being factory pre lested. For bis reason, a ‘refil! capacity is quoted and not ail from dry’ figure. + ENSURE THAT ALL SERVICING PERSONNEL ARE AWARE OF THE LEVEL PLUG POSITION (UNDERSIDE OF GEARBOX). CIRCUMSTANCES HAVE OCCURRED WHERE THE INCORRECT SCREW HAS BEEN UNDONE RESULTING IN REVERSE BRAKE BAND DISTURBANCE, SUCH DISTURBANCE WILL RESULT IN PERMANENT OAMAGE AND WILL RESULT IN GEARBOX REPLACEMENT WHICH IS NOT SUBJECT TO WARRANTY. Parts information: Nol apoteable Warranty information: Not apolcable TECHIWOAL BULLET T9C080 ISSUE 1 eNeusH Poge Bot 5 (NG Rover Group Ls 2002