gearbox LAND ROVER DISCOVERY 1995 Workshop Manual

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
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

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.

44AUTOMATIC GEARBOX
22
REPAIR
13.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 suitable washer
to give required end-float.
NOTE: If damage is apparent to bolts they
should be replaced.
14.Refit torque converter into housing using torque
converter handles 18G1501. Check dimension
converter fixing boss to converter housing face is
50 mm. This shows converter is properly seated
in housing.
15.Refit gearbox/transfer box assembly.
See
LT230T Transfer Gearbox
GEAR SELECTOR-INTERLOCK
For remove and refit of gear selector interlock.
See
ELECTRICAL, Repair, Gear Selector-Interlock

ZF
1
SPECIFICATIONS, TORQUE TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
Coupling shaft to mainshaft 42*......................................................................
Filler tube to sump 68.....................................................................................
Gear change lever to gearbox 25...................................................................
Cooler pipe adaptor to gearbox 42.................................................................
Securing screws - clutch F 10.........................................................................
Securing screw - parking pawl 10...................................................................
Securing screws - pump 10............................................................................
Intermediate plate plugs (M20) 50..................................................................
Intermediate plate plugs (M14) 40..................................................................
Bell housing mounting bolts 46.......................................................................
Governor mounting screws 10........................................................................
Extension housing bolts 23.............................................................................
Control unit mounting bolts 8.........................................................................
Sump plug 10..................................................................................................
Mounting screws for sump 8..........................................................................
Drive plate to converter 39*.............................................................................
Gearbox to engine 42.....................................................................................
Strut (threaded end) 42...................................................................................
Bottom cover to converter housing 9.............................................................
Cover - converter housing 9...........................................................................
Drive plates to crankshaft adaptor 40*............................................................
Adaptor to crankshaft 84.................................................................................
NOTE: * These bolts must have threads coated with Loctite 270 prior to assembly.
Torque values below are for all screws and bolts used except for those that are specified otherwise.
METRIC Nm
M5 6......................................................................................................
M6 9......................................................................................................
M8 25.....................................................................................................
M10 45...................................................................................................
M12 90...................................................................................................
M14 105..................................................................................................
M16 180..................................................................................................
UNC / UNF
1/4 9......................................................................................................
5/16 24...................................................................................................
3/8 39.....................................................................................................
7/16 78...................................................................................................
1/2 90.....................................................................................................
5/8 136....................................................................................................

44AUTOMATIC GEARBOX
2
SPECIFICATIONS, TORQUE ZF GEARBOX DATA
Axial end float 0.2 to 0.4 mm.
From torque converter boss to torque converter
housing face 50 mm
Freewheel cage assembly to ring gear; minimum
clearance 0.1 mm
Output shaft above cylinder F assembly; dimension
10.00 mm
A cylinder protrusion above gearbox front face not
more than 8.5 mm

ZF
1
SERVICE TOOLS AUTOMATIC GEARBOX HOLDING FIXTURE
NOTE: This fixture enables ZF gearbox to be held securely during bench sited repairs. It can be
manufactured to details given, or purchased under service tool number LST 118.

44AUTOMATIC GEARBOX
2
SERVICE TOOLS

ZF
3
SERVICE TOOLS AUTOMATIC GEARBOX
LRT-44-001 Front and rear oil seal replacer.
LST 108
LRT-44-002 Selector linkage setting gauge.
LST 109
LRT-44-003 Oil pump rotation sleeve and end float
LST 111 gauge.
LRT-44-004 Kickdown cable remover.
LST 112