washer fluid LAND ROVER DISCOVERY 2002 User Guide

CLUTCH - TD5
33-1-6 DESCRIPTION AND OPERATION
Description
General
The clutch system is a diaphragm type clutch operated by a hydraulic cylinder. The drive plate is of the rigid centre
type with no integral damping springs. The flywheel is of the dual mass type with damping springs integral with the
flywheel. The clutch requires no adjustment to compensate for wear.
Hydraulic clutch
The hydraulic clutch comprises a master cylinder, slave cylinder and a hydraulic reservoir. The master and slave
cylinders are connected to each other hydraulically by plastic and metal pipes. The plastic section of the pipe allows
ease of pipe routing and also absorbs engine movements and vibrations.
The master cylinder comprises a body with a central bore. Two ports in the body connect the bore to the hydraulic
feed pipe to the slave cylinder and the fluid reservoir. The bore is also connected to a damper which prevents engine
pulses being transferred hydraulically to the clutch pedal. A piston is fitted in the bore and has an external rod which
is attached to the clutch pedal with a pin. Two coil springs on the clutch pedal reduce the effort required to depress
the pedal.
The master cylinder is mounted on the bulkhead and secured with two bolts. The cylinder is connected to the shared
brake/clutch reservoir on the brake servo by a braided connecting hose.
The slave cylinder is located on the left hand side of the gearbox housing and secured with two bolts. A heat shield
is fitted to protect the underside of the slave cylinder from heat generated from the exhaust system. The slave cylinder
comprises a cylinder with a piston and a rod. A port in the cylinder body provides the attachment for the hydraulic feed
pipe from the master cylinder. A second port is fitted witha bleed nipple used for removing air from the hydraulic
system after servicing. The piston rod locates on a clutch release lever located in the gearbox housing. The rod is
positively retained on the release lever with a clip.
Clutch mechanism
The clutch mechanism comprises a flywheel, drive plate, pressure plate, release lever and a release bearing. The
clutch mechanism is fully enclosed at the rear of the engine by the gearbox housing.
A clutch release bearing sleeve is attached in the gearbox housing with two bolts and located on two dowels. A spigot
with a ball end is formed on the release bearing sleeve and provides amounting and pivot point for the clutch release
lever. A dished pivot washer is located on the ball of the spigot. When the release lever is located on the ball, the pivot
washer seats against the rear face of the release lever. A spring clip is located on the lever and the pivot washer and
secures the lever on the spigot. A small bolt retains the spring clip in position.
The release lever is forked at its inner end and locates on the clutch release bearing carrier. The outer end of the
release lever has a nylon seat which locates the slave cylinder piston rod. A second nylon seat, positioned centrally
on the release lever, locates on the ball spigot of the release bearing sleeve and allows the release lever to pivot freely
around the ball.
The clutch release bearing locates on the clutch release lever and release bearing sleeve. The bearing is retained on
a carrier which has two flats to prevent the carrier rotating on the release lever. A clip retains the release lever on the
carrier. The bearing and carrier are not serviceable individually.

CLUTCH - V8
33-2-6 DESCRIPTION AND OPERATION
Description
General
The clutch system is a conventional diaphragm type clutch operated by a hydraulic cylinder. The clutch requires no
adjustment to compensate for wear.
Hydraulic clutch
The hydraulic clutch comprises a master cylinder, slave cylinder and a hydraulic reservoir, which is also shared with
the braking system. The master and slave cylinders are connected to each other hydraulically by plastic and metal
pipes. The plastic section of the pipe allows ease of pipe routing and also absorbs engine movements and vibrations.
The master cylinder comprises a body with a central bore. Two ports in the body connect the bore to the hydraulic
feed pipe to the slave cylinder and the brake/clutch fluid reservoir. A piston is fitted in the bore and has an external
rod which is attached to the clutch pedal with a pin. Two coiled springs on the clutch pedal reduce the effort required
to depress the pedal.
The master cylinder is mounted on the bulkhead in the engine compartment and secured with two bolts. The cylinder
is connected to the shared brake/clutch reservoir on the brake servo by a braided connecting hose.
The slave cylinder is located on the left hand side of the gearbox housing and secured with two bolts. A heat shield
protects the underside of the cylinder from heat generated from the exhaust system. The slave cylinder comprises a
cylinder with a piston and a rod. A port in the cylinder body provides the attachment for the hydraulic feed pipe from
the master cylinder. A second port is fitted with a bleed nipple for removing air from the hydraulic system after
servicing. The piston rod locates on a clutch release lever located in the gearbox housing. The rod is positively
retained on the release lever with a clip.
Clutch mechanism
The clutch mechanism comprises a flywheel, drive plate, pressure plate, release lever and a release bearing. The
clutch mechanism is fully enclosed at the rear of the engine by the gearbox housing.
A clutch release bearing sleeve is attached in the gearbox housing with two bolts and located on two dowels. A spigot
with a ball end is formed on the release bearing sleeve and provides a mounting and pivot point for the clutch release
lever. A dished pivot washer is located on the ball of the spigot. When the release lever is located on the ball, the pivot
washer seats against the rear face of the release lever. A spring clip is located on the lever and the pivot washer and
secures the lever on the spigot. A small bolt retains the spring clip in position.
The release lever is forked at its inner end and locates on the clutch release bearing carrier. The outer end of the
release lever has a nylon seat which locates the slave cylinder piston rod. A second nylon seat, positioned centrally
on the release lever, locates on the ball spigot of the release bearing sleeve and allows the release lever to pivot freely
around the ball.
The clutch release bearing locates on the clutch release lever and the release bearing sleeve. The bearing is retained
on a carrier which has two flats to prevent the carrier rotating on the release lever. A clip retains the release lever on
the carrier. The bearing and carrier are not serviceable individually.

MANUAL GEARBOX - R380
37-22 REPAIRS
Refit
1.Using a suitable solvent clean seal housing
mating faces.
2.Clean seal recess, bearings and bearing races.
3.Lubricate new oil seal and fit using a suitable
mandrel into housing.
4.Fit input shaft front bearing track using a press
and suitable mandrel.
5.Apply sealant, Part No. STC 4404 to seal
housing.
6.Position seal housing, fit new bolts and tighten
by diagonal selection to 25 Nm (18 lbf.ft).
7.Clean bell housing mating faces, dowels and
dowel holes.
8.Position bell housing, fit bolts and tighten to 75
Nm (55 lbf.ft).
9.Clean release bearing sleeve mating faces,
dowel and dowel holes.
10.Position release bearing sleeve, fit bolts and
tighten to 25 Nm (18 lbf.ft).
11.Examine clutch release fork pivot points for
wear and replace as required.
12.Apply a smear of Molybdenum disulphide
grease to pivot points and position release
fork.
13.Fit retaining clip ensuring it locates over pivot
point washer, fit release fork bolt and tighten to
10 Nm (7 lbf.ft).
14.Clean release bearing and bearing sleeve
mating faces.
15.Apply smear of Molybdenum disulphide grease
to release bearing sleeve.
16.Fit release bearing and secure with retaining
peg.
17.Fit gearbox assembly.

+ MANUAL GEARBOX - R380,
REPAIRS, Gearbox - V8.
Cooler - oil - gearbox - Diesel
$% 37.24.02
Remove
1.Remove intercooler.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Intercooler.
2.Position absorbent cloth under each gearbox
oil cooler hose connection to collect spillage.
3.Push against coupling release ring and
disconnect both fluid hoses from oil cooler.
CAUTION: Always fit plugs to open
connections to prevent contamination.
4.Remove screw securing oil cooler to radiator.

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-35
Refit
1.Clean oil seal running surfaces.
2.Lubricate oil seal with transmission fluid.
3.Fit new seal into converter housing using tool
LRT-44-001.
4.Fit tool LRT-44-010 to torque converter.
5.Align oil pump drive and fit torque converter to
gearbox.
6.Remove tool LRT-44-010 from torque
converter.
7.Fit torque converter retaining strap.
8.Fit automatic gearbox.
l

+ AUTOMATIC GEARBOX -
ZF4HP22 - 24, REPAIRS, Gearbox -
convertor and transfer gearbox - Diesel.
l

+ AUTOMATIC GEARBOX -
ZF4HP22 - 24, REPAIRS, Gearbox -
convertor and transfer gearbox - V8.
Housing - torque converter
$% 44.17.01
Remove
1.Remove torque converter oil seal.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Torque converter and oil
seal.
2.Remove 18 bolts and plain washers securing
torque converter and intermediate plate to
gearbox casing. Note the position of the 4 bolts
that have sealant applied to the bolt threads
and 6 bolts, (outer ring), which are shorter.
3.Hold input shaft in position and carefully
remove the converter housing and intermediate
plate from gearbox casing.
4.Note the position of the Torrington race on the
forward clutch hub and the thrust washer which
will stay attached to the intermediate plate by
fluid adhesion.
5.Remove and discard intermediate plate gasket.
6.Remove thrust washer from intermediate plate.
7.Separate converter housing from intermediate
plate.
M44 1343
M44 1345

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-37
Gasket - intermediate plate
$% 44.20.11
Remove
1.Remove torque converter oil seal.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Torque converter and oil
seal.
2.Remove 12 bolts and plain washers securing
converter housing and intermediate plate to
gearbox casing. Note the position of the 4 bolts
that have sealant applied to the bolt threads.
3.Hold input shaft in position and carefully lift off
converter housing and intermediate plate as an
assembly. Note the position of the Torrington
race on the forward clutch hub, and the thrust
washer which will stay attached to the
intermediate plate by fluid adhesion.
4.Remove and discard intermediate plate gasket.
5.Remove thrust washer from intermediate plate.Refit
1.Clean intermediate plate and mating face on
gearbox casing.
2.Apply Petroleum Jelly to new gasket and
position on gearbox casing.
3.Apply Petroleum Jelly to thrust washer and
Torrington race.
4.Correctly position Torrington race and thrust
washer to forward clutch hub.
5.Position converter housing and intermediate
plate assembly to gearbox casing.
6.Clean bolts and plain washers and old sealant
from 4 bolt threads.
7.Apply High Formular Hylomar sealant to 4
longer bolt threads and fit bolts in position
shown.
8.Fit remaining bolts and tighten progressively in
a diagonal sequence to 46 Nm (34lbf. ft).
9.Place LRT-44-003/1 into pump housing, tighten
screws to secure LRT-44-003/1 to input shaft.
10.Clamp a suitable steel base to converter
housing flange.
M44 1344
M44 1345
M44 1344
M44 1358
LRT-44-003/1

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-38 REPAIRS
11.Mount DTI gauge and position gauge probe
onto LRT-44-003/1 and zero gauge.
12.Check that the axial end-float is between 0.2 to
0.4 mm (0.008 to 0.016 in). If end-float in not
within limits, replace existing thrust washer,
positioned at rear of intermediate plate, with a
suitable thickness thrust washer to give the
required end-float.
13.Remove DTI gauge and base plate.
14.Fit torque converter oil seal.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Torque converter and oil
seal.
Intermediate plate
$% 44.17.20
Remove
1.Remove intermediate plate gasket.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Gasket - intermediate plate.
2.Remove selective thrust washer from
intermediate plate.
3.Remove 2 M14 Allen plugs from intermediate
plate, remove and discard sealing washers.
4.Remove 2 M20 plugs from intermediate plate,
remove and discard sealing washers.
5.Remove 2 oil cooler pipe adaptors from
intermediate plate.
6.Remove 8 bolts securing fluid pump to
intermediate plate and carefully remove pump
from intermediate plate.
2443
M44 1356
3
M44 1336

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-39
7.Note position and remove pump locating dowel.
8.Remove and discard 'O' ring from pump
housing.
9.Remove 6 bolts securing converter housing to
intermediate plate, and release intermediate
plate from converter housing.Refit
1.Clean intermediate plate and mating faces with
a lint free cloth.
2.Position intermediate plate to converter
housing, fit bolts and tighten evenly to 46 Nm
(34 lbf.ft)
3.Fit new sealing washers to M14 Allen plugs, fit
plugs and tighten to 40 Nm (30 lbf.ft).
4.Fit new sealing washers to M20 plugs, fit plugs
and tighten to 50 Nm (37 lbf.ft).
5.Fit oil cooler adaptors and tighten to 42 Nm (30
lbf.ft)
6.Clean pump housing and mating face on
intermediate plate with lint free cloth.
7.Lubricate new 'O' ring with transmission fluid
and fit to pump housing.
8.Position pump locating dowel into intermediate
plate.
9.Align pump to dowel and position in
intermediate plate.
10.Fit bolts and tighten in a diagonal sequence to
10 Nm (7 lbf.ft)
11.Position LRT-44-003/1 into pump and check
that the pump rotors turn freely.
12.Fit intermediate plate gasket.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Gasket - intermediate plate.
M44 1341
M44 1357
M44 1342
LRT-44-003/1

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-46 REPAIRS
7.Remove temperature sensor and discard
sealing washer.
Refit
1.Use new sealing washer and tighten
temperature sensor to 14 Nm (10 lbf.ft).
2.Fit cooler, engage with radiator and secure with
screw.
3.Connect temperature sensor multiplug.
4.Ensure connections are clean and fit hoses to
cooler.
5.Fit intercooler.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Intercooler.
6.Check and if necessary top up gearbox fluid.
Cooler - fluid - V8
$% 44.24.10
Remove
1. If fitted: Remove engine oil cooler.

+ ENGINE - V8, REPAIRS, Cooler -
engine oil.
2.Disconnect fluid temperature sensor multiplug.
3.Position absorbent cloth under each gearbox
cooler hose connection to collect spillage.
4.Push against coupling release ring and
disconnect both fluid hoses from cooler.
CAUTION: Always fit plugs to open
connections to prevent contamination.
5.Remove screw and release cooler from
radiator.
6.Carefully move radiator towards engine and
remove cooler.

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-47
7.Remove temperature sensor and discard
sealing washer.
Refit
1.Use new sealing washer and tighten
temperature sensor to 14 Nm (10 lbf.ft).
2.Fit cooler, engage with radiator and secure with
screw.
3.Connect temperature sensor multiplug.
4.Ensure connections are clean and fit hoses to
cooler.
5. If fitted:Fit engine oil cooler.

+ ENGINE - V8, REPAIRS, Cooler -
engine oil.
6.Check and if necessary top up gearbox fluid.
Valve body assembly
$% 44.40.01
Remove
1.Remove gearbox oil filter.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Filter - oil.
2.Remove 2 bolts securing speed sensor
harness bracket to valve body.
3.Disconnect multiplug from gearbox housing.
4.Using a 30 mm socket, remove nut securing
multiplug connector block to gearbox housing.

REAR AXLE
51-8 REPAIRS
Refit
1.Clean pinion oil seal recess and pinion flange.
2.Lubricate oil seal lip with clean differential oil.

+ CAPACITIES, FLUIDS AND
LUBRICANTS, Lubrication.
3.Using tool LRT-51-010, fit pinion oil seal.
4.Fit pinion flange and securing bolt and washer.
Using tool LRT-51-003 to restrain pinion
flange, tighten pinion flange securing bolt to
100 Nm (74 lbf.ft).
5.Using a tubular drift, fit centralising peg to
pinion flange. Ensure that large diameter part of
centralising peg is below pinion flange
mounting surface.
6.Position propeller shaft and align reference
marks.
7.Fit nuts and bolts securing flexible coupling to
pinion flange and tighten to 76 Nm (55 lbf.ft).
8.Remove stand(s) and lower vehicle.
9.Check differential oil level.

+ MAINTENANCE, PROCEDURES,
Front and rear axle.
M51 0047A
LRT-51-003