torque LAND ROVER DISCOVERY 1995 Repair Manual

ZF
1
REPAIR LT230T TRANSFER GEARBOX WITH AUTOMATIC
GEARBOX ASSEMBLY - V8i
Service repair no - 44.20.04
Removal from V8i engine
The assembled transfer gearbox, automatic gearbox
and torque converter is removed from underneath the
vehicle. Use a transmission hoist with an adaptor
plate for securing the assembly to the hoist. The
adaptor can be manufactured locally to the drawing
below or purchased from:- Straight Set Engineering,
England. Tel.01909 480055
WARNING: When using a transmission
hoist it is essential to follow the hoist
manufacturer's instructions.

ZF
3
REPAIR 19.Disconnect rear propeller shaft to output flange,
and tie to one side.
20.Repeat instructions 18 and 19 on front propeller
shaft to main gearbox.
21.Remove bolts retaining silencer front and rear
securing brackets and tie silencer to one side.
22.Disconnect oil cooler feed and return pipes from
bottom and side of main gearbox.
23.Release cooler pipes from clamp at engine sump
and remove distance piece.
24.Blank pipe ends and unions.
25.Move oil cooler pipes clear of transmission and
tie aside.
26.Disconnect selector cable from operating lever.
27.Disconnect inhibitor switch at multiplug.
28.Attach adaptor plate to hoist.
29.Remove two bolts from transfer gearbox rear
cover.
30.Raise hoist to align adaptor plate with transfer
gearbox and transmission. Secure to transfer
gearbox at rear cover with two bolts removed.
31.Adjust hoist to take weight of transmission.
32.Remove nuts and bolts securing right transfer
gearbox mounting bracket to chassis.
33.Repeat for the left mounting bracket. Removal of
these fixings will also free speedometer
transducer bracket
34.Remove right side mounting bracket to flexible
mounting rubber retaining nut.
35.Lower hoist until rear brake drum clears
passenger footwell. Check engine does not
crush any components while lowering.
36.Remove clip and clevis pin from park brake
lever.
37.Remove clip securing outer brake cable
38.The park brake cable is now free.
39.Disconnect leads from transfer gearbox
temperature sensor and differential lock warning
light switch.
40.Remove ties securing breather pipes to harness.
41.Remove bell housing access plate complete with
gasket.
42.Rotate engine, using crankshaft pulley, until two
access holes are visible in drive plate/ring gear
assembly through bell housing bottom cover
opening.
43.Identify an access hole and bolt hole to aid
reassembly.
44.Remove bolts securing drive plate to convertor
through access holes.
45.Rotate crankshaft half turn to access and
remove remaining bolts.
46.Disconnect oil dipstick tube at main gearbox.
47.Remove bolt at bell housing and detach dipstick
tube. Blank pipe end and union.
48.Position hoist jack channel under engine and
support using a wooden block.
49.Remove bell housing to engine securing bolts,
also detach harness bracket from bell housing.
50.Ease transmission rearwards to allow access to
secure torque converter in bell housing.
51.Lower hoist and complete removal of
transmission.
Refit
52.Ensure torque converter is retained in bell
housing.
53.Secure transmission to adaptor plate on lifting
hoist.
54.Raise hoist and locate transmission with engine.
55.Remove torque converter retainer.
56.Complete attachment of transmission to engine
and fit bell housing bolts. Fit the dipstick tube
bracket and harness bracket to their respective
bolts.
57.Complete refitting by reversing removal
procedure. Note the following important points.
58.Drive plate to torque converter bolts are to be
coated with Loctite 290 prior to assembly.
59.Refill transfer and main gearboxes with correct
grade oil.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
60.Check operation of parking brake and adjust as
necessary.
See SECTION 10, Maintenance,
Vehicle Interior

44AUTOMATIC GEARBOX
4
REPAIR LT230T TRANSFER GEARBOX WITH AUTOMATIC
GEARBOX ASSEMBLY - Tdi
Service repair no - 44.20.04
Removal from Tdi engine
The assembled transfer gearbox, automatic gearbox
and torque converter is removed from underneath the
vehicle. Use a transmission hoist with an adaptor
plate for securing the assembly to the hoist.
WARNING: When using a transmission
hoist it is essential to follow the hoist
manufacturer's instructions.

44AUTOMATIC GEARBOX
6
REPAIR 13.Remove starter.
14.Working through starter aperture note position of
torque converter flexible drive plate to facilitate
refitting.
15.Remove the four torque convertor to flexible
drive securing bolts, rotating engine to gain
access to each individual bolt.
16.Raise vehicle on four post ramp [hoist].
17.Drain lubrication oil from transfer and main
gearboxes.
18.Disconnect speedometer cable from transfer
gearbox and disconnect associated clipping.
19.Remove rear propeller shaft.
See PROPELLER
SHAFTS, Overhaul, Flexible Coupling
20.Disconnect front propeller shaft at transfer
gearbox and tie to one side.
21.Remove exhaust front pipe.
22.Remove bolts securing front and centre silencer
mounting brackets and tie silencer to one side.
23.Disconnect oil cooler pipes from gearbox.
24.Blank off pipes and union connections.
25.Remove bolt securing retaining bracket to sump
and move cooler pipes aside.
26.Disconnect selector cable from lever on side of
gearbox.
27.Disconnect inhibitor switch multi-plug.
28.Disconnect park brake cable from linkage to park
brake lever.
29.Disconnect electrical connections from
differential lock switch on transfer gearbox.
30.Remove two lower bolts from transfer gearbox
input bearing support plate.
31.Assemble approved support cradle to
transmission hoist.32.Raise hoist and secure cradle to transfer
gearbox input bearing support plate using bolts
removed.
33.Disconnect gearbox mounting brackets from
chassis cross member.
34.Remove chassis cross member.
35.Lower transmission sufficiently to allow access
to items attached to top of gearbox.
36.Remove left hand gearbox mounting bracket
assembly.
37.Remove ties from breather pipes and harness.
38.Remove nut securing gearbox oil filler/dip stick
tube to bell housing.
39.Release union nut at gearbox sump and remove
filler/dipstick tube. Fit blanking plugs.
40.Support engine using a wooden block with a
suitable ramp [hoist] jack.
41.Remove nut securing kick down cable bracket to
bell housing.
42.Remove two bolts securing top of bell housing to
flywheel housing.
43.Remove nuts securing bell housing to flywheel
housing and withdraw transmission assembly
from engine.
44.Fit a suitable torque converter retaining strap to
the bell housing.
45.Remove hoist and transmission from under
vehicle.
46.Fit lifting eyes to transmission.
47.Using suitable chains and lifting tackle take
weight of transmission assembly.
48.Remove bolts securing transmission cradle to
transfer box and withdraw hoist complete with
cradle.
49.Refit bolts to cover plate.

ZF
7
REPAIR Accessories removal/fitting
If fitting a replacement transmission assembly to the
vehicle, remove the following items from the existing
assembly and fit to the replacement.
CAUTION: It is important to remove the
spacer from the extension shaft and fit
onto the replacement unit.
50.Breather pipe union and washers from main
gearbox.
51.Breather pipe, union and washers from transfer
gearbox.
52.Main gearbox selector lever.
53.RH mounting bracket assembly.
54.Oil cooler pipe unions.
55.Fit blanks to all apertures where unions have
been removed and blank off pipe ends.
Refit
1.Fit transmission to cradle and hoist.
2.Locate hoist under vehicle and remove torque
convertor retaining strap.
3.Ensure low range gear is engaged.
4.Apply approved sealant to bell housing face.
5.Carefully raise assembly, align bell housing with
flywheel housing and bring mating faces
together.
6.Fit nuts and bolts to secure transmission to
engine.
7.Locate electrical wiring and breather pipes to
position.
8.Secure kick down cable clip to bell housing.
9.Raise hoist sufficiently to take weight.
10.Remove block and jack from engine sump.
11.Fit filler/dipstick tube to gearbox sump and
secure bracket to bell housing.
12.Apply Loctite to torque convertor bolts
13.Working through starter aperture refit the four
torque convertor to flexible drive securing bolts,
rotating crankshaft to gain access to bolt
locations.
14.Refit starter and heatshield.
15.Secure breather pipes and harness with ties.
16.Fit left hand mounting bracket assembly to
gearbox.
17.Raise transmission and support with a suitable
ramp [hoist] jack.
18.Remove two bolts securing transmission to
cradle, lower hoist and remove from under
vehicle.
19.Apply Loctite to above bolts and fit to transfer
gearbox input bearing support plate.
20.Fit chassis cross member.21.Secure gearbox mounting brackets to chassis
cross member.
22.Remove ramp [hoist] jack.
23.Connect electrical leads to differential lock
switch.
24.Connect inhibitor switch multi-plug.
25.Connect selector cable to lever on side of
gearbox.
26.Connect oil cooler pipes to gearbox and secure
retaining bracket to gearbox sump.
27.Secure silencer to chassis and refit exhaust front
pipe.
28.Refit front propeller shaft to transfer gearbox.
29.Refit rear propeller shaft.
See PROPELLER
SHAFTS, Overhaul, Flexible Coupling
30.Connect speedometer cable to transfer gearbox.
31.Refill transfer gearbox with correct grade of
lubricating oil.
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information,
Recommended Lubricants and Fluids
32.Lower ramp [hoist] to ground level.
33.Reconnect turbo-charger hose to inter-cooler.
34.Reconnect top hose to radiator.
35.Refill cooling system with correct mixture of
coolant.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
36.Reconnect kick down cable to fuel injection
pump.
37.Secure breather pipe clip to rear of cylinder
head.
38.Engage harness with clips along top of
bulkhead.
39.On left hand drive vehicles only, connect
multi-plug to top of brake fluid reservoir.
40.Refit insulation pad to rocker cover and inlet
manifold, secure with oil filler cap.
41.Refit gaiter and knob to transfer gear lever.
42.Select high range gear.
43.Reconnect battery terminals.
44.Refill main gearbox with correct grade of
lubricating oil.
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information,
Recommended Lubricants and Fluids

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
18
REPAIR REPLACING TORQUE CONVERTER
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.Fit new torque converter using torque converter
handles 18G1501. Check dimension from
converter fixing boss to converter housing face is
50 mm. This shows converter is correctly seated
in housing.
4.Refit gearbox and transfer box assembly.
See
LT230T Transfer Gearbox
ELIMINATING LEAKS ON PUMP HOUSING
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 and pump assembly,
discard gasket.
5.Remove eight hexagonal bolts on rear of pump.

ZF
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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

ZF
21
REPAIR REPLACING PUMP
Service repair no - 44.32.01
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 bolts (inner ring pattern).
4.Remove bell housing and pump assembly from
gearbox case, discard gasket.
5.Remove eight bolts on rear of pump.
6.Screw in two bolts,diagonally opposite each
other, tap lightly using a soft headed mallet to
free pump assembly from intermediate plate.
7.Fit new pump assembly, aligning dowel with hole
in intermediate plate, press pump housing home.
8.Secure pump housing to intermediate plate
using eight hexagonal bolts. Tighten to
10 Nm.
9.Place bell housing and intermediate plate
assembly on bench, front face up. Using oil
pump rotation sleeve LST111, check that pump
gears rotate freely.
10.Before replacing intermediate plate/bell housing
assembly check that thrust washer and axial
cage are seated on A clutch housing.
11.Place new gasket and disc washer onto bell
housing and intermediate plate assembly using
a Petroleum Jelly.
12.Fit bell housing and intermediate plate assembly,
tighten twelve bolts to
46 Nm.