gearbox LAND ROVER DISCOVERY 1995 Owners Manual

44AUTOMATIC GEARBOX
8
REPAIR INHIBITOR SWITCH
Service repair no - 44.15.19
Remove
1.Site vehicle on a four post ramp [hoist].
2.Disconnect battery negative lead. Raise vehicle.
3.Disconnect inhibitor switch multi plug.
4.Remove inhibitor switch retaining plate.
5.Remove inhibitor switch.
6.Remove 'O' ring seal.
7.Clean inhibitor switch.
Refit
8.Clean mating face on casing.
9.Fit and lubricate new 'O' ring seal to switch.
10.Fit switch to casing.
11.Secure with retaining plate and bolt.
12.Connect multiplug to harness.
13.Reconnect battery and remove vehicle from
ramp [hoist].
SELECTOR SHAFT OIL SEAL
Service repair no - 44.15.34
Renew
1.Site vehicle on a four post ramp [hoist].
2.Disconnect battery negative lead.
3.Raise vehicle.4.Detach heat shield at front exhaust pipe to
manifold.
5.Disconnect electrics from Lambda sensors.
6.Remove catalytic converter assembly.
7.Remove chassis cross-member from under
gearbox.
8.Engage low range gear in the transfer gearbox.
9.Support transfer gearbox with a jack or
transmission hoist.
10.Remove transfer gearbox chassis mounting
bracket nuts and bolts. Note location of
speedometer cable bracket for refit.
11.Lower transmission to allow access to selector
shaft.
12.Remove selector lever from shaft.
13.Remove selector shaft seal from casing.
14.Clean selector shaft and seal mating faces.
15.Fit centre section of special tool LST 114 over
selector shaft.
16.Lubricate new oil seal and position seal on tool.
17.Fit tool outer sleeve and screw on nut to drive
seal into housing.
18.Remove tool from shaft.
19.Refit selector lever to shaft.
20.Raise transmission and secure mounting
brackets to chassis. Ensure speedometer cable
bracket is secured. Tighten bolts to
30Nm.
21.Remove support jack.
22.Refit chassis cross-member.
23.Refit catalytic converter assembly.
24.Connect electrics to Lambda sensors.
25.Connect heat shield front pipe to manifold.
26.Connect battery.
27.Check/top up gearbox oil level.

ZF
9
REPAIR OIL SUMP
Service repair no - 44.24.05
Remove
1.Site vehicle on a four post ramp [hoist].
2.Disconnect battery negative lead.
3.Raise vehicle.
4.Drain oil and refit plug with new seal.
5.Detach heat shield at front exhaust pipe to
manifold.
6.Disconnect electrics from Lambda sensors.
7.Remove catalytic converter assembly.
8.Remove chassis cross-member from under
gearbox.
9.Disconnect dipstick tube at oil sump. Loosen
securing bolt at bell housing and move dipstick
aside.
10.Remove clamps securing oil sump. Note their
locations for refit and withdraw sump.
11.Remove gasket and clean gasket mating faces.Refit
12.Refit oil sump using a new gasket.
13.Connect dipstick tube to oil sump and tighten
bolt at bell housing.
14.Refit chassis cross member.
15.Refit catalytic converter assembly
16.Connect electrics to Lambda sensors.
17.Connect heat shield front pipe to manifold.
18.Connect battery.
19.Refill gearbox using correct grade of oil.
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended Lubricants and
Fluids

44AUTOMATIC GEARBOX
10
REPAIR OIL SCREEN
Service repair no - 44.24.07
Renew
1.Site vehicle on a four post ramp [hoist].
2.Disconnect battery negative lead.
3.Raise vehicle.
4.Drain oil and refit plug with new seal.
5.Detach heat shield at front exhaust pipe to
manifold.
6.Disconnect electrics from Lambda sensors.
7.Remove catalytic converter assembly.
8.Remove chassis cross-member from under
gearbox.
9.Disconnect dipstick tube at oil sump. Loosen
securing bolt at bell housing and move dipstick
aside.
10.Remove clamps securing oil sump. Note their
locations for refit and withdraw sump.
11.Remove gasket and clean gasket mating faces.
12.Remove securing screws and detach oil screen
and suction pipe, taking care to retain suction
pipe spacer, discard 'O' ring seal.13.Detach suction pipe from oil screen, discard 'O'
ring seal.
14.Clean oil screen and blow out with airline.
15.Clean suction pipe.
16.Fit new 'O' ring seals to oil screen using light
grease to aid assembly.
17.Fit oil screen and suction pipe with spacer and
secure with three bolts.
18.Refit oil sump using a new gasket.
19.Connect dipstick tube to oil sump and tighten
bolt at bell housing.
20.Refit chassis cross-member.
21.Refit catalytic converter assembly
22.Connect electrics to Lambda sensors.
23.Connect heat shield front pipe to manifold.
24.Connect battery.
25.Refill gearbox oil system using correct grade of
oil.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids

ZF
11
REPAIR CONTROL UNIT
Remove
1.Site vehicle on a four post ramp [hoist].
2.Disconnect battery negative lead.
3.Raise vehicle.
4.Drain oil and refit plug with new seal.
5.Detach heat shield at front exhaust pipe to
manifold.
6.Disconnect electrics from Lambda sensors.
7.Remove catalytic converter assembly.
8.Remove chassis cross-member from under
gearbox.
9.Disconnect dipstick tube at oil sump. Loosen
securing bolt at bell housing and move dipstick
aside.
10.Remove clamps securing oil sump. Note their
locations for refit and withdraw sump.
11.Remove gasket and clean gasket mating faces.
12.Remove securing screws and detach oil screen
and suction pipe, taking care to retain suction
pipe spacer, discard 'O' ring seal.
13.Remove securing screws and detach control unit
from casing.

44AUTOMATIC GEARBOX
12
REPAIR Oil seal replacement
14.Remove circlips and springs from control unit.
Note locations of long and short springs.
15.Using seal replacer/remover LST113 remove
and discard seals.
16.Clean control unit, springs and circlips and check
that they are satisfactory for further use.
17.Fit new seals to control unit using LST113,
ensure seals are fully seated.
18.Fit springs to locations noted during removal and
secure with circlips.
Refit
19.Fit control unit to gearbox, locating throttle valve
behind cam and engaging selector quadrant with
manual valve.
20.Loosely fit securing screws.21.Manually open throttle linkage to full throttle
position.
22.Engage special tool LST 109 between control
unit and throttle valve pin.
23.Set correct distance between control unit and
cam.
24.Remove special tool and close throttle.
25.Fit new 'O' ring seals to oil screen using light
grease to aid assembly.
26.Fit oil screen and suction pipe with spacer and
secure with three bolts.
27.Refit oil pan using a new gasket.
28.Connect dipstick tube to oil sump and tighten
bolt at bell housing.
29.Refit chassis cross member.
30.Refit catalytic converter assembly
31.Connect electrics to Lambda sensors.
32.Connect heat shield front pipe to manifold.
33.Connect battery.
34.Refill gearbox oil system using correct grade of
oil.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids

ZF
13
REPAIR KICKDOWN CABLE
Service repair no - 44.15.01
Remove
1.Site vehicle on a four post ramp [hoist].
2.Select neutral 'N' gear lever.
3.Disconnect battery negative lead.
4.Disconnect kickdown cable at throttle linkage.
5.Release outer cable locknut.
6.Disconnect cable from mounting bracket.
7.Release cable from bracket attached to cylinder
head.
8.Feed cable through to underside of vehicle.
9.Raise vehicle on ramp [hoist].
10.Drain oil and refit plug with new seal.
11.Detach heat shield at front exhaust pipe to
manifold.
12.Disconnect electrics from Lambda sensors.
13.Remove catalytic converter assembly.
14.Remove chassis cross-member from under
gearbox.
15.Disconnect dipstick tube at oil sump. Loosen
securing bolt at bell housing and move dipstick
aside.
16.Remove clamps securing oil sump. Note their
locations for refit, and withdraw sump.
17.Pull kickdown inner cable to fully open valve
cam. Wedge cam in this position.
18.Release cable from cam by pushing inner cable
into outer casing and detaching cable nipple
from cam.
19.Using special tool LST112 compress cable tangs
and remove cable from gearbox.
20.If cable is to be refitted remove 'O' ring seal and
clean cable assembly.
Refit
21.Fit new 'O' ring seal to cable and lubricate seal.
22.Fit cable to gearbox casing ensuring it is
correctly seated.
23.Fit inner cable nipple to its location on cam.
NOTE: When a new cable is fitted, to help
locate nipple to cam, introduce a curve
into the cable. Do not bend or kink cable.24.Remove wedge from cam and ensure nipple
remains engaged.
25.Feed free end of cable assembly into engine
compartment.
26.Refit oil pan using a new gasket.
27.Connect dipstick tube to oil sump and tighten
bolt at bell housing.
28.Refit chassis cross-member
29.Refit catalytic converter assembly
30.Connect electrics to Lambda sensors.
31.Connect heat shield front pipe to manifold.
32.Lower vehicle on ramp [hoist].
33.Fit cable to bracket at cylinder head.
34.Locate cable in mounting bracket, do not tighten
locknut.
35.Fit cable to throttle linkage.
36.Ensure throttle linkage is fully closed.
37.Adjust outer cable to achieve a gap of 0,25 to
1,25mm (dimension 'A') between end of outer
cable and crimped collar on inner cable.
38.Tighten locknuts and recheck gap.
NOTE: If fitting a new cable, and collar on
inner cable is loose, measure distance 'B'
on old cable. Crimp collar on new cable to
this dimension.
39.Reconnect battery negative lead.
40.Refill gearbox oil using correct grade of oil.
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended Lubricants and
Fluids

44AUTOMATIC GEARBOX
14
REPAIR EXTENSION HOUSING
Service repair no - 44.20.18
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 securing bolts and withdraw extension
housing from over coupling shaft. Remove and
discard gasket.
6.Place extension housing on bench and remove
oil seal.
7.Ensure that all surfaces are clean and housing is
free from damage. If damage is found and
housing has to be renewed remove dowels from
face of existing housing and fit to new housing.
8.Using special tool LST108 fit new oil seal to
housing.Refit
9.Fit extension housing to gearbox, with a new
gasket, ensuring oil seal is not damaged by
extension shaft.
10.Secure housing with nine bolts. Tighten to
23
Nm.
11.Refit transfer gear lever housing to top of
extension housing. Tighten to
25 Nm.
12.Refit mounting bracket to extension housing.
Tighten to
52 Nm.
13.Refit transfer gear box.See TRANSFER
GEARBOX, Repair, LT230T Transfer Gearbox
14.Refill automatic gearbox lubrication system with
correct grade of 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
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
17
REPAIR PARKING PAWL MECHANISM
Service repair no - 44.28.07
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 guide plate bolt.
8.Remove plate and guide plate from gearbox
case.
9.Remove pin, pawl and spring.
CAUTION: When removing assembly.
Avoid damaging parts which could weaken
spring tension.
10.Inspect all parts for wear or damage. Replace if
necessary.
Refit
11.Fit pin and leg spring, locate spring correctly.
12.Fit pawl to pin. Locate spring leg into hole in
pawl to create tension in spring.
13.Fit plate and guide plate. Tighten to
10 Nm.
14.Push governor assembly with parking wheel
onto output shaft until seated.
NOTE: Apply petroleum jelly to 'O' ring.
Ensure seal rings are snapped together
and seated.
15.Fit new gasket to rear of gearbox. Fit extension
housing, taking care not to damage seal or
assembly.
16.Fit extension shaft with spacer if Tdi and
retaining bolt with new 'O' ring.
17.Fit extension housing, tighten nine bolts to
23Nm.
18.Fit transfer gear selector housing, tighten three
bolts to
25 Nm.
19.Refit transfer box.