Oil leakage from transmission oil cooler pipes

OIL LEAKAGE FROM TRANSMISSION OIL COOLER PIPES

Model

Range Rover

Affected vehicles

All diesel derivatives with manual transmission up to VIN XA 420122

Date

1999-06-02

Reference

Bulletin 0012, CDS ref L8516bu

Bulletin text

Range Rover

AFFECTED RANGE:

All diesel derivatives with manual transmission up to VIN XA 420122

PROBLEM:

OIL LEAKAGE FROM TRANSMISSION OIL COOLER PIPES

CAUSE:

Vibration induced fracture of the oil cooler pipes at the gearbox end.

ACTION:

• = Install the revised support bracket kit UBK100180 as detailed below to prevent reoccurrence of the failure. • = Replace the oil cooler pipes with those listed in PARTS INFORMATION .

Bulletin N o : 0012 L8516bu 1 02.06.99

NOTE: It is likely that only one pipe will have failed, however, both pipes should be replaced as fatigue damage may have already occurred to the pipe which is not leaking.

Replace the pipes and support brackets as follows:

1. Disconnect the battery.

2. Raise the vehicle on a four post lift.

3. Remove the M6 x 20 screw, complete with saddle clamp and small spacer washer securing the cooler pipes to the underside of the engine mounting bracket. Retain these parts.

4. Disconnect the cooler pipes from the oil cooler.

5. Disconnect the cooler pipes from the connections at the rear of the gearbox and remove pipes from vehicle.

Vehicles up to start of 97MY - VIN VA 346794

1. Disconnect the clutch fluid pipe from the support bracket and remove bracket.

2. From kit UBK100180, fit the new support bracket (A in illustration) and reconnect the clutch fluid pipe.

3. Remove the bolt securing the harness bracket to the rear of the clutch housing, (location C in illustration).

4. From the kit, position the new cooler pipe bracket B to the rear of the clutch housing at location C and with the harness bracket placed over the new bracket, secure them both with the M6 x 16 screw from the kit.

5. Position the new oil cooler pipes ESR2922 and ESR2924 at the gearbox end and fit connections finger tight.

6. Position the front end of the cooler pipes to the oil cooler and fit finger tight.

7. Attach screws M6 x 20, complete with saddle clamps and thick spacer washers, ( D in illustration ) to new brackets A and B. Finger tighten only.

8. Attach the original M6 x 20 screw, complete with saddle clamp and small spacer washer to the underside of the engine mounting bracket and finger tighten.

9. Ensure that the flats on the cooler pipes are aligned with the underside of the engine mounting bracket and tighten cooler pipe connections as follows: Gearbox end - torque to 20Nm. Oil cooler end - torque to 30Nm.

NOTE: the torque figure for the connections at the gearbox end have been revised downwards from that quoted in the Workshop Manual. Please ensure that the new figure of 20Nm is adhered to. Do not over tighten.

10. Tighten all saddle clamp to bracket screws to 9Nm.

11. Bleed clutch hydraulic system - Workshop Manual repair number 33.15.01 refers.

12. Start engine and confirm that new installation is free from leaks.

13. Check gearbox oil level and top up if necessary.

Vehicles from VIN VA 346794 to XA 420122.

1. Disconnect the clutch fluid pipe from its support bracket.

2. Release two clips and lower gearbox acoustic cover.

3. Remove the clutch fluid pipe support bracket.

4. From kit UBK100180, fit the new support bracket ( A in illustration ).

5. From the kit, fit the new bracket B to the rear of the clutch housing and secure with the M6 x 16 screw C.

6. Refit gearbox acoustic cover.

7. Fit the clutch fluid pipe to the new support bracket B.

8. Position the new oil cooler pipes ESR3958 and ESR3959 at the gearbox end and fit connections finger tight.

9. Position the front end of the cooler pipes to the oil cooler and fit finger tight.

10. Attach screws M6 x 20, complete with saddle clamps and thick spacer washers ( D in illustration ), to new brackets A and B. Finger tighten only.

11. Attach the original M6 x 20 screw, complete with saddle clamp and small spacer washer to the underside of the engine mounting bracket and finger tighten.

12. Ensure that flats on cooler pipes are aligned with underside of engine mounting bracket and tighten cooler pipe connections as follows: Gearbox end - torque to 20Nm. Oil cooler end - torque to 30Nm.

13.Attach the original M6 x 20 screw, complete with saddle clamp and small spacer washer to the underside of the engine mounting bracket and finger tighten.

NOTE: the torque figure for the connections at the gearbox end have been revised downwards from that quoted in the Workshop Manual. Please ensure that the new figure of 20Nm is adhered to. Do not over tighten.

14. Tighten all saddle clamp to bracket screws to 9Nm.

15. Bleed clutch hydraulic system - Workshop Manual repair number 33.15.01 refers.

16. Start engine and confirm that new installation is free from leaks.

17. Check gearbox oil level and top up if necessary.

PARTS INFORMATION:

ESR2922 Hose - transmission oil cooler - inlet - up to VIN VA 346794

ESR2924 Hose - transmission oil cooler -return - up to VIN VA 346794

ESR3958 Hose - transmission oil cooler - inlet - from VIN VA 346794 to XA 420122

ESR3959 Hose - transmission oil cooler -return - from VIN VA 346794 to XA 420122

UBK100180 Kit - transmission oil cooler pipes - up to VIN XA 420122

CONTENTS OF KIT UBK100180

Bracket - clutch & oil cooler pipes

Bracket - oil cooler pipes

Screw - M6 x 16

Screws - M6 x 20 Saddle clamps Spacer washers

WARRANTY CLAIMS: Use Complaint Code: 3F2E

Use S.R.O.: 12.60.89/33 Time allowance: 1.60Hrs

Qty Illustration ref

1 A

1 B

1 C

2 2 D 2