Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236).Jaguar S-Type (X200) V6-3.0L Technical Service Bulletin # S204-R136 Date:

Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236).Jaguar S-Type (X200) V6-3.0L Technical Service Bulletin # S204-R136 Date:

001201

Recall - Front Lower Ball Joint Inspection/Replacement

S204-R136

S-TYPE

DATE 11/00

Amended 12/00

MODEL

2000-01 MY

S-TYPE

2000 Jaguar S-Type (X200) V6-3.0L Page 44

VIN

L00001-L92349

Recall R136 - Front Lower Ball Joints - Check Torque or Replace

Remove and destroy Bulletin S204-R136, dated 11/00. Replace with this Bulletin.

Revisions are shown with asterisks and black bars.

Issue:

As a result of ongoing process assessments, Jaguar has identified a safety-related defect on a number of S-TYPE vehicles.

On the vehicles involved, it is possible that an under-torque condition may exist on the front lower ball joint assembly This may result in a high

bending fatigue loading condition on the joint. In some cases the high bending loads could result in a fracture in the first thread of the ball stud that

could then lead to separation of the lower control arm from the vertical link.

Jaguar has made the decision to recall all S-TYPE vehicles in the above VIN range to check and, if necessary, replace the front lower ball joint. If

replacement is required, the easiest way to do this is to replace the complete vertical link assembly This work will be performed free of charge to the

customer.

*Only a very small number of the vehicles checked will require replacement parts.*

*WARNING:

NO DEALER STOCK SHOULD BE RELEASED UNTIL THIS CHECK AND ANY NECESSARY RECTIFICATION IS CARRIED OUT.

Customer vehicles, with a VIN prior to L92349, MUST be checked before releasing the vehicle to the customer.*

Jaguar is writing to all affected customers in North America (copy of letter is shown) requesting them to contact an authorized Jaguar Dealer as soon

as possible to arrange for the lower ball joint assembly to be checked and, if necessary, replaced at the earliest opportunity.

Parts Information

2000 Jaguar S-Type (X200) V6-3.0L Page 45

2000 Jaguar S-Type (X200) V6-3.0L Page 46

2000 Jaguar S-Type (X200) V6-3.0L Page 47

Warranty Information

Action

Check and, if necessary, replace the required components on all S-TYPE vehicles that are within the affected VIN range.

The workshop procedure for checking vehicles, as well as, for replacing components is outlined in this bulletin.

Jaguar has shipped a torque wrench to dealers that makes it possible to perform this check without the need to remove the wheel and tire assembly

By not removing the wheel and tire assembly the current dynamic balance characteristics will be retained.

LOWER BALL JOINT SECURING NUT TORQUE CHECK

1. Set torque wrench to 80 Nm and apply to the lower ball joint retaining nut (Illustration 1).

2000 Jaguar S-Type (X200) V6-3.0L Page 48

Note:

Hold the ball joint stud with a suitable wrench to prevent possible rotation while performing the 80 Nm check (Illustration 2).

2. If the torque wrench reaches 80 Nm without moving, reset the torque wrench to 150 Nm and torque tighten the nut.

Note:

To show that the retaining nut has been tightened to 150 Nm, a painted identification mark must be added to the nut.

3. If the retaining nut moves prior to reaching 80 Nm or the nut is visually loose, then the vertical link assembly will have to be replaced.

^ Dismantle the vertical link (ball joint) and inspect the lower arm, checking the stud-through hole for damage caused by looseness.

Note:

Also check for deterioration of the cone face; e.g. pitting, scoring or an elliptical shape.

^ If the arm is damaged the lower arm will need to be replaced along with the vertical link.

Note:

After replacing the lower arm, vertical link or both, the painted identification mark needs adding to the retaining nut.

REPLACING LOWER BALL JOINT/VERTICAL LINK

If one or both lower ball joint securing nuts fail the check, the corresponding vertical link will need to be replaced using the following

procedure:

1. Remove front brake disc for access. See JTIS 206-03 (SRO 70.10.10).

2. Remove the three push-pins from the inner fender skirt, then position the skirt aside to access the anti-lock brake (ABS) sensor electrical

connector.

*Caution:

Do not remove the ABS sensor and wire from the hub assembly. The sensor 0-ring may be damaged.*

3. Disconnect the ABS sensor from the vehicle wiring harness. Detach the ABS sensor wiring from the retaining clips.

2000 Jaguar S-Type (X200) V6-3.0L Page 49

4. Loosen and remove front hub securing bolts (Illustration 3).

5. Remove front hub from vertical link (Illustration 4).

6. Loosen, but do not remove upper wishbone ball joint securing nut (hold ball joint stud to prevent rotation).

7. Loosen and remove tie rod end to vertical link securing nut (hold ball joint stud to prevent rotation).

8. Disconnect tie rod end from vertical link.

9. Loosen and remove lower wishbone ball joint securing nut (hold ball joint stud to prevent rotation).

10. Disconnect vertical link from lower wishbone.

11. Finally remove securing nut from the upper wishbone ball joint (hold ball joint stud to prevent rotation).

12. *Remove vertical link and front disc shield from the vehicle as an assembly.*

13. Clean components and mating surfaces.

14. Check the condition of the lower ball joint mounting hole in the lower wishbone for damage caused by looseness.

Note:

Check for deterioration of the cone face e.g. pitting, scoring or an elliptical shape.

Note:

If no damage is visible proceed to step 34 (install and align new vertical link to upper wishbone) of this workshop procedure.

15. If the mounting hole is damaged, the lower wishbone will need to be replaced.

On vehicles equipped with 3.0 V6 engines, the generator plastic cover will have to be removed for access if the right hand lower wishbone is

to be replaced and must be reinstalled after completing the alignment check and adjust.

^ Displace and remove generator cover upper fir tree fastener.

^ Loosen and remove generator cover/front under tray securing screw.

^ Loosen and remove generator cover rear securing screw.

^ Remove generator cover.

2000 Jaguar S-Type (X200) V6-3.0L Page 50

16. On all vehicles, loosen, remove and discard stabilizer link arm to lower wishbone-securing nut (Illustration 5). (Hold ball joint stud to stop

rotation.)

17. Reposition link arm away from lower wishbone.

18. Loosen and remove front shock absorber to lower wishbone-securing bolt. Discard the nut (Illustration 6).

19. Loosen and remove steering rack securing bolts (Illustration 7). Discard the nut.

20. Displace and reposition steering rack for access.

21. Loosen, remove and discard lower wishbone front and rear securing nuts.

22. Remove and discard lower wishbone front and rear bolts.

Note:

2000 Jaguar S-Type (X200) V6-3.0L Page 51

If cam bolts are already installed, retain them for reuse.

23. Displace and remove lower wishbone.

Note:

When replacing a damaged lower wishbone on a vehicle with the early type front bushings, the lower wishbone on the opposite side must

also be replaced since both sides must have the same style bushings. The later style bushings can be identified by polyurethane inserts in

the forward mounting bushing. Earlier type bushings do not have the polyurethane inserts.

24. Position and align new lower wishbone to no. 1 and No. 2 front beams.

25. Install new wishbone cam bolts if required, as described.

*Caution:

Do not tighten newly installed cam bolts and securing nuts until the alignment check and adjust procedure is performed with the vehicle

lowered, to prevent the wishbone bushes being prestressed during normal operation.*

FRONT CAM BOLT

Install the bolt from the rear, with the cam lobe down (Illustration 8).

Note:

Ensure the cam lobe is fitted centrally between the cam guides on the no. 1 cross-member.

Note:

Fit but do not fully tighten the lock nut, until after the alignment check.

REAR CAM BOLT

Install the bolt from the rear, with the cam lobe down (Illustration 9).

Note:

Ensure the cam lobe is fitted centrally between the cam guides on the no. 2 cross-member.

2000 Jaguar S-Type (X200) V6-3.0L Page 52

NOTE:

Fit but do not fully tighten the lock nut, until after the alignment check.

26. Reposition and align lower wishbone to front damper.

27. Install and tighten front damper to lower wishbone-securing nut/bolt. Torque setting 175 Nm.

28. Fit but do not fully tighten new cam bolt securing nuts.

29. Reposition and align steering rack.

30. Install and tighten steering rack securing nuts/bolts. Torque setting 103 Nm.

31. Connect stabilizer link arm to lower wishbone.

32. Install and tighten the nut that secures the stabilizer link arm to the lower wishbone. (Hold ball joint stud to stop rotation). Torque setting 55

Nm.

33. Install and align new vertical link to upper wishbone.

34. Fit but do not fully tighten upper wishbone to vertical link securing nut (hold ball joint to prevent rotation).

35. Reposition vertical link to lower wishbone.

36. Fit but do not fully tighten lower wishbone ball joint securing nut (hold ball joint stud to prevent rotation).

37. Install and fully tighten lower wishbone ball joint securing nut with torque wrench to 150 Nm.

38. Position vertical link to tie rod ball joint.

39. Connect tie rod ball joint to vertical link.

40. Install and tighten ball joint securing nut (hold ball joint stud to prevent rotation). Torque setting 100 Nm.

41. *If the disc shield is not already installed on the vertical link, * reinstall disc shield using the 1/4" rivets supplied. See JTIS 206-03 (SRO

2000 Jaguar S-Type (X200) V6-3.0L Page 53

70.10.18).

*Note:

It is imperative that the brake disc shield is reinstalled with the three 1/4" rivets supplied in the kit. Installing the shield with a smaller rivet

will result in a rattle condition and customer dissatisfaction.*

42. Install and align hub assembly

43. Install and tighten hub assembly securing bolts. Torque setting 90 Nm.

44. Route the ABS sensor wiring and attach the wiring to the retaining clips. Connect the ABS sensor wiring to the vehicle harness.

45. Position the inner fender skirt and install the pushpins.

Final tighten upper ball joint securing nut (hold ball joint stud to prevent rotation). Torque setting 90 Nm.

46. Reinstall front disc. See JTIS 206-03 (SRO 70.10.10).

47. Reinstall front road wheels to the previously marked position and partially tighten the wheels nuts by hand. Lower the vehicle and fully tighten

the wheels nuts to a torque setting of 128 Nm.

48. If only one or both *vertical links* are replaced, the vehicle will have to undergo a geometry check and adjust for front wheel alignment only

(Toe). See JTIS, section: 204-00.

If one or both *lower wishbones* are replaced, the vehicle will have to undergo a full steering geometry and front wheel alignment check and

adjust. See JTIS, section: 204-00.

49. On V6 vehicles only, reinstall the generator cover after the alignment has been checked and adjusted with the new cam bolts installed and nuts

final tightened. Install and align generator cover front edge fits between front under tray and beam one.

Install and tighten generator cover rear securing screw. Install and tighten generator cover/front under shield securing screw. Install and secure

generator cover upper fir tree fastener.

50. Lower the vehicle.

2000 Jaguar S-Type (X200) V6-3.0L Page 54