clutch LAND ROVER DISCOVERY 1995 Repair Manual

ZF
3
FAULT DIAGNOSIS ROADTEST 3 = CHECKS
12-13-14-15-16-17-18-19-20-21-22-23
D SELECTED FROM REST
LIGHT THROTTLE START
CHECK 12
Check 1st 2nd upshift speed and quality.
CHECK 13
Check 2nd 3rd upshift speed and quality.
CHECK 14
Check 3rd 4th upshift speed and quality.
NOTE: This shift is usually very difficult to
detect but can be confirmed by a 200 rpm
drop in engine speed.
CHECK 15
Check speed and quality of shift into direct drive
clutch, confirmed by 300 rpm drop in engine speed.
NOTE: An intermediate throttle position
engagement of 4th and the direct drive
clutch, which is indicated by a fall of
500rpm in engine speed.
CHECK 16
At approximately 88 kph (55 mph) depress throttle to
kickdown - gearbox should change down to 2nd -
release throttle to re-engage 4th direct drive clutch
continue to accelerate gently.
CHECK 17
At approximately 128 kph (80 mph) depress throttle to
kickdown - gearbox should change down to 3rd -
release throttle to re-engage 4th direct drive clutch
and continue to accelerate gently.CHECK 18
At approximately 138 kph (85 mph) select 3rd,
gearbox should change immediately down to 3rd.
Release throttle.
CHECK 19
De-accelerate to approximately 47 kph (30 mph)
depress throttle to kickdown - geabox should
downshift to 1st gear, continue accelerating at full
throttle until 3rd gear is attained. To do this you will
have repeated check 2 of Test 1.
CHECK 20
At 128 kph (80 mph) select 2nd no downshift should
occur. Release throttle.
CHECK 21
At 104 kph (65 mph) an automatic downshift into 2nd
gear should occur. Continue to de-accelerate.
CHECK 22
At 88 kph (55 mph) select 1st. No downshift should
occur. Continue to de-accelerate.
CHECK 23
With 1 selected 2nd gear engaged continue to
de-accelerate and at 45 kph (28 mph) the box should
automatically downshift to 1st gear after which no
upshifts will occur in this selector position.
END OF ROADTEST

44AUTOMATIC GEARBOX
6
FAULT DIAGNOSIS 1. A Clutch assembly
2. B Clutch assembly

ZF
7
FAULT DIAGNOSIS 1. C,C' and D Clutch assembly

ZF
9
FAULT DIAGNOSIS 1. E and F Clutch assembly

44AUTOMATIC GEARBOX
10
FAULT DIAGNOSIS FAULT SYMPTOMS
SYMPTOM 1 - Intermittent drive and high pitched
noise
FAULT - Low fluid level or restricted filter
SYMPTOM 2 - No drive in reverse
Select 'D'
ú No drive
FAULT - Continue with Symptom 3
ú Drives forward
FAULT - Reverse gear interlock valve
seized
Select '1'
ú No engine braking
FAULT - Clutch brake 3
SYMPTOM 3 - No drive from rest with 'D' selected
Select '1'
ú Vehicle drives
FAULT - No 2 freewheel
ú No drive
Carry out main line pressure check
ú Normal pressure
FAULT - Clutch A
ú No pressure
FAULT - Blocked filter or pump failure
ú Low pressure
FAULT - Restricted filter or sticking primary
regulator
SYMPTOM 4 - Slip in all forward gears
Carry out main line pressure check
ú No pressure
FAULT - Blocked filter or pump failure
ú Low pressure
FAULT - Restricted filter or sticking primary
regulator
ú Normal pressure
FAULT - Clutch 'A'SYMPTOM 5 - Harsh engagement 'N' to 'D'
Check engine idle speed
Carry out main line pressure check
ú High pressure
FAULT - Primary regulator stuck
ú Normal pressure
FAULT - Clutch 'A' or damper for clutch'A'
SYMPTOM 6 - Fierce shift or flare 1st to 2nd shift
Check engine idle speed
Carry out mainline pressure check
ú High pressure
FAULT - Continue with symptom 5
ú Normal pressure
FAULT - Modulator valve or dampers for
clutch brake CB1 and/or clutch brake CB2
FAULT - Clutch brake CB1 and/or clutch
brake CB2
SYMPTOM 7 - Fierce shift or flare 2nd to 3rd
Carry out mainline pressure check
ú High pressure
FAULT - Continue with symptom 5
ú Normal pressure
FAULT - Modulator valve or clutch 'B'
damper
FAULT - Clutch 'B'
SYMPTOM 8 - No 3rd gear
FAULT - 2-3 shift valve
FAULT - Clutch 'B'
SYMPTOM 9 - No 4th gear 'D' selected
FAULT - 4th to 3rd downshift valve stuck or
3rd to 4th upshift valve stuck
FAULT - Clutch brake 4

ZF
11
FAULT DIAGNOSIS SYMPTOM 10 - None or harsh engagement of
direct drive clutch
NOTE: The direct drive clutch will only
engage if 4th gear is engaged at 40 to 45
mph.
Carry out road test pressure check with gauge
connected to torque converter.
ú Normal pressure
FAULT - Failed direct drive clutch
ú Pressures correct but remains high
FAULTS POSSIBLE -
Direct drive clutch and torque converter
control valve stuck
Hysteresis valve stuck
Direct drive clutch control valve stuck
SYMPTOM 11 - Direct drive clutch shift point
incorrect or at low speed
NOTE: Direct drive clutch engagement at
low speed will cause vibration in the
torque converter
Carry out mainline and torque converter pressure
check
ú Normal pressure
FAULT - Governor valve sticking
ú Low or incorrect pressure
FAULTS POSSIBLE -
Direct drive clutch and torque converter
control valve sticking.
Hysteresis valve stuck.
Direct drive clutch control valve stuck.
SYMPTOM 12 - Drives in 'D' but immediately
upshifts to 3rd
FAULT - 2nd to 3rd shift valve stuck.
SYMPTOM 13 - With 'D' selected vehicle starts in
2nd
FAULTS POSSIBLE -
1st and 2nd shift valve stuck.
Governor sleeve sticking.
SYMPTOM 14 - With 'D' selected vehicle starts in
3rd
FAULTS POSSIBLE -
1st to 2nd and 2nd to 3rd shift valves stuck.
Governor sleeve sticking.SYMPTOM 15 - No kickdown 4th to 3rd
FAULT - 4th to 3rd kickdown valve stuck.
SYMPTOM 16 - Upshifts/downshifts and kickdown
shifts at incorrect road speeds
Check throttle kickdown cable adjustment
Carry out main line pressure check
ú Normal pressure
FAULT - Governor valve sticking
ú Incorrect pressure
FAULTS POSSIBLE -
Incorrect throttle valve adjustment
Primary regulator sticking
SYMPTOM 17 - No upshifts at light throttle
FAULTS POSSIBLE
Governor valve sticking
Shift valves sticking
SYMPTOM 18 - No engine braking '3' selected 3rd
gear
FAULT - Clutch 'C'
SYMPTOM 19 - Delayed or no downshift occurs
when making a manual selection from '3' to '2'
FAULTS POSSIBLE -
2nd and 3rd upshift valve sticking.
Governor valve sticking.
'2' Position interlock valve sticking.
SYMPTOM 20 - At speeds below 28 mph when
making a manual selection from '2' to '1',
downshift is delayed or does not occur
FAULTS POSSIBLE -
Governor sticking.
1st to 2nd shift valve sticking.
'1' Position interlock valve sticking.
SYMPTOM 21 - '1' Selected 1st gear no engine
braking
FAULT - Clutch brake 3
SYMPTOM 22 - '2' Selected 2nd gear no engine
braking
FAULT - Clutch brake 1
SYMPTOM 23 - Vehicle drives forward in 'N'
FAULT - Clutch 'A' stuck

ZF
15
REPAIR GOVERNOR ASSEMBLY
Service repair no - 44.22.01
Remove
1.Remove transfer gearbox.
See TRANSFER
GEARBOX, Repair, LT230T Transfer Gearbox
2.Drain oil from automatic gearbox.
3.Remove bolts securing left hand mounting
bracket to extension housing and withdraw
bracket.
4.Remove transfer gear lever housing securing
bolts and move housing aside.
5.Remove extension housing ensuring seal is not
damaged, remove and discard gasket.
6.Remove extension shaft retaining bolt, withdraw
shaft and discard 'O' ring seal. If Tdi vehicle
remove spacer.
7.Remove governor assembly.
8.Remove park gear from governor assembly.
9.Detach governor housing.
10.Remove security clip and counter weight.
11.Remove and discard 'O' ring seal from output
shaft and three seal rings from 'F' clutch
housing.
12.Clean all components.
13.If necessary detach parking pawl by removing
guide plates and withdrawing mechanism.Refit
14.Refit parking pawl mechanism if removed.
15.Fit and lubricate new seal rings to 'F' clutch
housing shaft, ensure they are correctly seated.
16.Apply petroleum jelly to a new 'O' ring seal. Fit to
output shaft
17.Fit park gear to governor assembly tightening
screws to correct torque.
18.Fit governor assembly to output shaft.
19.Fit extension shaft with spacer if Tdi. Fit new 'O'
ring under bolt head.
20.Fit extension housing, avoid damaging seal.
Tighten to
23 Nm.
21.Refit transfer gear lever housing to extension
housing.
22.Refit mounting bracket to extension housing.
Tighten to
52 Nm.
23.Refit transfer gearbox.See TRANSFER
GEARBOX, Repair, LT230T Transfer Gearbox
24.Refill automatic gearbox with correct grade of oil.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids

44AUTOMATIC GEARBOX
16
REPAIR GOVERNOR HUB
Service repair no - 44.22.04
Remove
1.Remove transfer box.
See TRANSFER
GEARBOX, Repair, LT230T Transfer Gearbox
2.Remove transfer gear selector housing.
3.Loosen nine bolts holding extension housing.
4.Remove extension housing ensuring that seal is
not damaged, discard gasket.
5.Remove extension shaft and retaining bolt with
'O' ring. If Tdi vehicle remove spacer.
6.Remove governor assembly with parking wheel.
7.Remove two screws holding governor housing.
8.Remove two bolts, remove parking wheel.
Discard governor hub.
9.Remove security clip and counter-weight.
10.Remove 'O' ring from output shaft and discard.
11.Remove three seal rings from 'F' clutch housing
shaft.
12.Inspect all parts for damage or wear, replace if
necessary.
Refit
13.Fit counterweight and security clip into new
governor hub.14.Secure governor housing to governor hub.
Tighten to
10Nm.
15.Fit parking wheel to governor hub. Tighten to10
Nm.
16.Fit three new seal rings onto F clutch housing
shaft, fit 'O' ring onto output shaft.
NOTE: To aid fitting of 'O' ring apply
petroleum jelly.
17.Push governor assembly and parking wheel onto
output shaft until seated.
NOTE: Apply petroleum jelly to 'O' ring.
Ensure seal rings are snapped together
and seated.
18.Fit new gasket to rear of gearbox. Fit extension
housing, avoid damaging seal.
19.Fit extension shaft,and spacer if Tdi, apply
Loctite 270 to retaining bolt. Using a new 'O'
ring, tighten bolt to
42 Nm.
20.Tighten nine extension housing nine bolts to23
Nm.
21.Fit transfer gear selector housing, tighten three
bolts to
25 Nm.
22.Refit transfer box.

ZF
19
REPAIR 6.Screw in two bolts, diagonally opposite each
other. Tap lightly using a soft headed mallet to
remove pump assembly from intermediate plate.
7.Remove shaft sealing ring and 'O' ring from
pump housing and discard.
8.Using oil seal replacer LST108 fit shaft seal ring
into pump housing.
9.Fit 'O' ring onto circumference of pump housing.
10.Align dowel with hole in intermediate plate and
press pump housing home.11.Fit pump housing to intermediate plate, tighten
eight bolts to
10 Nm.
12.Place bell housing and intermediate plate
assembly on bench, front face up. Using oil
pump rotation sleeve LST111, check that pump
gears rotate freely.
13.Before fitting intermediate plate and bell housing
assembly,check that thrust washer and axial
cage are seated on A clutch housing.
14.Place gasket and disc washer onto bell housing
and intermediate plate assembly using
Petroleum Jelly.
15.Fit bell housing and intermediate plate assembly
to gearcase. Tighten twelve bolts to
46 Nm.
16.Place end float gauge LST111 onto pump
housing and check that axial play is between
0.2-0.4 mm. Replace existing washer, situated at
rear of intermediate plate, with a suitable washer
to give required end float.
17.Refit torque converter into housing using torque
converter handles 18G1501, checking that
dimension from converter fixing bolt boss to
converter housing face is 50 mm. This shows
converter is properly seated in housing.
18.Refit gearbox/transfer box assembly.
See
LT230T Transfer Gearbox

44AUTOMATIC GEARBOX
20
REPAIR ELIMINATING LEAKS BETWEEN GEARBOX
HOUSING AND INTERMEDIATE PLATE
1.Remove gearbox and transfer box assembly.
See LT230T Transfer Gearbox
2.Place gearbox on bench. Remove torque
converter using torque converter handles
18G1501, taking care not to damage torque
converter/oil pump housing oil seal.
3.Remove twelve hexagonal bolts (inner ring
pattern).
4.Remove bell housing/intermediate plate
assembly from gearbox case and discard
gasket.
5.Place new gasket onto intermediate plate using
Petroleum Jelly.
6.Before fitting bell housing assembly check that
thrust washer and axial cage are seated on A
clutch housing.
7.Fit bell housing assembly with disc washer to
gearcase. Tighten twelve bolts to
46Nm.
8.Place end-float gauge LST111 onto pump
housing and check that axial play is between
0.2-0.4 mm. Replace existing washer, situated at
rear of intermediate plate, with a suitable washer
to give required end-float.
9.Refit torque converter using torque converter
handles 18G1501. Checking that dimension
from converter fixing boss to converter housing
case is 50mm. This dimension shows converter
is properly seated.
10.Refit gearbox/transfer box assembly.
See
LT230T Transfer Gearbox