maintenance LAND ROVER DISCOVERY 2002 Repair Manual

TRANSFER BOX - LT230SE
REPAIRS 41-35
3.Fit new seal using tool LRT-41-012.
4.Position drive flange, fit new felt and steel
washers.
5.Position tool LRT-51-003 and tighten new
drive flange nut to 148 Nm (109 lbf.ft).
6.Position handbrake drum and tighten screw.
7.Tighten brake shoe adjuster bolt to 25 Nm (18
lbf.ft) then loosen one and a half turns.
8.Check that brake drum is free to rotate.
9.Fit propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
10.Top-up transfer box oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
Gasket - rear output shaft housing
$% 41.20.55
Remove
1.Drain transfer gearbox oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
2.Remove rear output shaft seal.

+ TRANSFER BOX - LT230SE,
REPAIRS, Seal - rear output shaft.
3.Mark output shaft housing to main casing for
assembly purposes.
4.Note position of shoulder bolt, remove 6 bolts
securing housing to main casing.
Refit
1.Clean output shaft housing, mating face on
main casing and sealant from bolt threads.
2.Apply sealant, Part No. STC 3254 to mating
flange on output shaft housing.
3.Fit output shaft housing to main casing.
4.Apply Loctite 290 to bolt threads.
5.Fit output shaft housing bolts and tighten by
diagonal selection to 45 Nm (33 lbf.ft).
6.Fit rear output shaft seal.

+ TRANSFER BOX - LT230SE,
REPAIRS, Seal - rear output shaft.
7.Fill transfer gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-26 REPAIRS
Refit
1.Clean shaft and seal housing.
2.Using a suitable adapter, fit new seal.
3.Position selector quadrant and connecting rod.
4.Position selector shaft and secure to quadrant
using new roll pin.
5.Fit valve body assembly.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Valve body assembly.
Gearbox - convertor and transfer
gearbox - Diesel
$% 44.20.04.99
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery earth lead.
3.Raise vehicle on a ramp.
4.Remove starter motor

+ CHARGING AND STARTING,
REPAIRS, Starter motor - diesel.
5.Remove 2 upper bolts securing gearbox
housing to engine.
6.Remove bolt securing closing plate to gearbox
housing.
7.Remove exhaust front pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - Td5, REPAIRS, Pipe - front.
8.Remove 3 nuts securing intermediate silencer
to tail pipe.
9.Release and remove silencer from rubber
mountings.
10.Drain automatic gearbox oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-27
11.Drain transfer gearbox oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
12.Remove front propeller shaft

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
13.Remove rear propeller shaft

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.
14.Remove and discard 3 bolts securing torque
converter to drive plate.
15.Remove handbrake drum retaining screw and
remove brake drum. 16.Remove 4 bolts from handbrake back plate,
release back plate and tie aside.
17.Remove clip securing high/low ratio selector
cable to transfer gearbox lever, remove 'C' clip
and remove outer cable from gearbox.
18.Disconnect 2 Lucars from differential lock
switch and multiplugs from high/low ratio switch
and neutral sensor.
19.Remove cable tie and multi plug from bracket
to transfer box.

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-30 REPAIRS
14.Secure gearbox breather pipes to bulkhead
clip.
15.Connect multiplugs to high/low ratio switch and
neutral sensor. Connect Lucars to differential
lock switch.
16.Position cable tie and multi plug to transfer box
bracket.
17.Connect high/low ratio cable to transfer box
and secure with retaining clips.
18.Position hand brake back plate and tighten
bolts to 75 Nm (55 lbf.ft).
19.Fit hand brake drum and tighten screw.
20.Remove bolts securing tool LRT-99-008A to
gearbox.
21.Rotate engine to align torque converter, fit new
bolts and tighten to 50 Nm (37 lbf.ft).
22.Fit rear propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.
23.Fit front propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
24.Fill transfer gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
25.Fill automatic gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
26.Position intermediate silencer and secure to
mounting rubbers.
27.Clean silencer and tail pipe mating faces.
28.Position new gasket to tail pipe and tighten
nuts to 25 Nm (18 lbf.ft).
29.Fit exhaust front pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - Td5, REPAIRS, Pipe - front.
30.Fit bolt securing closing plate to gearbox
housing and tighten to 7 Nm (5.2 lbf.ft).
31.Fit upper bolts securing gearbox housing to
engine and tighten to 50 Nm (37 lbf.ft).
32.Fit starter motor.

+ CHARGING AND STARTING,
REPAIRS, Starter motor - diesel.
33.Tighten remaining gearbox housing to engine
bolts to 50 Nm (37 lbf.ft).
34.Connect battery earth lead.
35.Fit battery cover and secure with fixings.
36.Check and adjust selector cable.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, ADJUSTMENTS, Cable - selector.
Gearbox - convertor and transfer
gearbox - V8
$% 44.20.04.99
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery earth lead.
3.Raise vehicle on a ramp.
4.Remove 8 bolts securing centre cross member
and remove cross member.
5.Remove exhaust front pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Front pipe.
6.Remove 3 nuts securing intermediate silencer
to tail pipe.
7.Release and remove silencer from rubber
mountings.
8.Drain automatic gearbox oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
9.Drain transfer gearbox oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
10.Remove front propeller shaft

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-34 REPAIRS
24.Fit front propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
25.Fill transfer gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
26.Fill automatic gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
27.Position intermediate silencer and secure to
mounting rubbers.
28.Clean silencer and tail pipe mating faces.
29.Position new gasket to tail pipe and tighten nuts
to 40 Nm (30 lbf.ft).
30.Fit exhaust front pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Front pipe.
31.Position centre cross member, fit bolts and
tighten to 26 Nm (19 lbf.ft).
32.Connect battery earth lead.
33.Fit battery cover and secure fixings.
34.Check and adjust selector cable.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, ADJUSTMENTS, Cable - selector.
Torque converter and oil seal
$% 44.17.07
Remove
1.Remove 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.
2.Remove retaining strap from torque convertor.
3.Fit tool LRT-44-010 to torque converter and
remove torque converter from gearbox.
4.Remove tool LRT-44-010 from converter.
5.Remove oil seal from converter housing.

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-41
Seal - rear extension housing
$% 44.20.18
Remove
1.Remove transfer box

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - Diesel.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - V8.
2.Drain automatic gearbox oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
3.Remove rear extension housing oil seal from
gearbox.
Refit
1.Clean oil seal recess in gearbox and running
surface on input shaft.
2.Lubricate oil seal running surface with
transmission oil. 3.Using tool LRT-44-001 fit oil seal to extension
housing.
4.Fit transfer box

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - Diesel.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - V8.
5.Fill automatic gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-42 REPAIRS
Gasket - rear extension housing.
$% 44.20.19
Remove
1.Drain automatic gearbox oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
2.Remove transfer gearbox.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - Diesel.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - V8.
3.Remove 9 bolts securing rear extension
housing to gearbox case and remove housing.
4.Remove and discard gasket. Reassembly
1.Clean rear extension and mating face.
2.Position new gasket to gearbox case.
3.Position rear extension housing and tighten
bolts to 25 Nm (18 lbf.ft).
4.Fit transfer gearbox.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - Diesel.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - V8.
5.Fill automatic gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-43
Parking pawl assembly.
$% 44.28.07
Remove
1.Drain automatic gearbox oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
2.Remove transfer gearbox.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - Diesel.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - V8.
3.Remove and discard 9 bolts securing extension
housing to gearbox case.
4.Remove extension housing and discard gasket. 5.Remove Torx screw and discard, lift off parking
pawl guide and guide plate.
6.Remove ratchet, spring and pivot pin.
7. Td5 models: Remove spacer from output
shaft.
8.Remove park lock gear.
9.Remove and discard 'O' ring from output shaft.
Refit
1.Clean park lock components.
2.Lubricate and fit new 'O' ring to output shaft.
3.Position park lock gear on the output shaft.
4. Td5 models: Fit the spacer.
CAUTION: Ensure that spacer is fitted on
output shaft - Tdi Models only. If spacer is
omitted, park gear and speed sensor may
move out of position.
5.Position pivot pin, spring and ratchet.
6.Position parking pawl guide and guide plate,
tighten Torx screw to 10 Nm (8 lbf.ft).
M44 1109B
97
8

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-44 REPAIRS
7.Clean extension housing and gearbox case.
8.Position new gasket to gearbox case.
9.Position extension housing and tighten bolts to
25 Nm (18 lbf.ft).
10.Fit transfer gearbox.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - Diesel.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - V8.
11.Fill automatic gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
Gasket - oil sump
$% 44.24.05
Remove
1.Raise vehicle on ramp.
2.Drain automatic gearbox oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
3.Remove 6 bolts and spacers securing oil sump
to gearbox, remove sump and discard gasket.
Refit
1.Clean oil sump and mating face.
2.Fit new gasket to oil sump, position sump to
gearbox.
3.Position spacers and tighten bolts to 8 Nm (6
lbf. ft).
4.Fill automatic gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
5.Lower vehicle.

PROPELLER SHAFTS
47-2 DESCRIPTION AND OPERATION
Description
General
Front and rear propeller shafts transmit the drive from the transfer box to the axles.
On vehicles from 03 model year fitted with the 4.6l V8 engine and 4HP24 transmission, the front propeller shaft is 15
mm (0.6 in) longer and the rear propeller shaft is 15mm (0.6 in) shorter than those used on vehicles with the 4.0l V8
and Td5 engines. This is to accomodate an increase in length of the 4HP24 transmission.
Front propeller shaft
1Hookes joint
2Grease nipple
3Universal joint
4Gaiter/Sliding spline joint
5Lubrication point
The front propeller shaft consists of a tube with a universal joint and a sliding spline joint at the front end, and a
Hookes joint at the rear end. The universal joint is bolted to the pinion flange of the front axle differential. The Hookes
joint is bolted to the front output shaft of the transfer box.
The Hookes joint is lubricated during manufacture and sealed for life. A grease nipple is installed in the universal joint
to lubricate the serviceable, sealed needle bearings of the joint. The sliding spline joint is sealed with a gaiter and
lubricated through a lubrication point on the tube. Because of the proximity of a chassis crossmember to the front
propeller shaft, the lubrication point is normally sealed with a grub screw. During maintenance, the grub screw is
temporarily replaced by a slave grease nipple to lubricate the sliding spline joint.