gearbox LAND ROVER DISCOVERY 1995 Workshop Manual

44AUTOMATIC GEARBOX
4
SERVICE TOOLS
LRT-44-005 Control unit oil seal remover/replacer.
LST 113
LRT-44-006 Selector shaft oil seal replacer.
LST 114
LRT-44-007 Line pressure test gauge.
18G.502A
LRT-44-008 Hose and adaptor.
18G.502K

PROPELLER SHAFTS
1
DESCRIPTION AND OPERATION PROPELLER SHAFT ALIGNMENT
Description
The front and rear propeller shafts have non-constant
velocity 'Hooks' type universal joints, with needle roller
bearings. The bearing cups are pre-packed with
lubricant on assembly and a grease nipple is fitted for
servicing as specified, in maintenance section.
Both shafts have Rilsan coated sliding splines to
accommodate the variation in distance between the
axles and transmission. The splines are pre-packed
with lubricant and sealed.
The rear shaft is fitted with a conventional joint at
gearbox end and the sliding joint sealed with a rubber
gaiter. An SGF rubber coupling is fitted at the
differential end of the shaft.
The front shaft which is shorter than the rear is
'Phased', with the joints at each end, A and B
mis-aligned as shown in RR4199.
The phasing is necessary on the front shaft only to
allow for greater variation in angular changes.
Catalyst vehicles
The front shaft is 'phased' as above but is of solid bar
construction.

PROPELLER SHAFTS
1
FAULT DIAGNOSIS VIBRATION HARSHNESS
1.Check that the propeller shaft universal joints
and sliding splines are not siezed or worn and
that the shafts are correctly aligned.
NOTE: In the event that both shafts are
satisfactory, but the vibration/harshness is
still present, the transfer box operation
and balance of the road wheels should be
checked.
For transfer box operation.
See TRANSFER
GEARBOX, Fault diagnosis, LT230T Transfer Box
- Oil Leaks
For balance of road wheels.See WHEELS AND
TYRES, Repair, Wheel Balancing

47PROPELLER SHAFTS
2
REPAIR 18.Press each cup into its respective yoke up to
lower land of circlip grooves. Damage may be
caused to cups and seals if cups pass this point.
19.Fit circlips and check no end float exists.
20.Engage spider in yokes of sliding member. Fit
bearing cups and circlips as described in
instructions 14 to 19.
21.Fit grease nipples to spider and sliding member.
22.Apply instructions 14 to 19 to opposite end of
propeller shaft.
23.Fit grease nipple and lubricate.
Refit
24.Fit propeller shafts to vehicle and tighten nuts to
47Nm
Refit FRONT propeller shaft so sliding joint end
of shaft is fitted to transfer gearbox.

47PROPELLER SHAFTS
4
REPAIR REAR PROPELLER SHAFT
Service repair no - 47.15.03
NOTE: SGF rubber coupling should be left
attached to propeller shaft. Only remove
coupling from propeller shaft if
replacement is required.
Remove
1.Scribe alignment marks on flanges at both ends
of propeller shaft to ensure correct refitting.
2.Remove three nuts and bolts securing flexible
coupling to axle flange.
3.Remove nuts securing propeller shaft flange to
transfer gearbox.
4.Raise propeller shaft at gearbox end detach
coupling from spigot at differential and withdraw
shaft.
NOTE: For replacement of spigot (pinion
flange centralising peg).
See REAR AXLE
AND FINAL DRIVE, Overhaul, Axle
Differential Assembly
Overhaul
Service repair no - 47.15.12
NOTE: Refer to front propeller shaft
overhaul procedure for gearbox end of
shaft. The SGF rubber coupling is a
non-serviceable item.
Refit
5.Locate flexible coupling over spigot, align
scribed marks and secure at transfer gearbox.
Tighten to
47 Nm.
6.Secure flexible coupling to axle flange with three
nuts and bolts and Tighten to
78 Nm.
FLEXIBLE COUPLING
NOTE: Flexible coupling should only be
removed if a new coupling is to be fitted.
Remove
1.Remove rear propeller shaft.
See Rear
Propeller Shaft.
2.Remove nuts and bolts securing flexible
coupling to propeller shaft.
Refit
3.Reverse removal procedure. Fit nuts and bolts.
Tighten to
78 Nm.

BRAKES
1
DESCRIPTION AND OPERATION BRAKES
Discovery vehicles have servo assisted brake
systems and the option of an anti-lock brake system.
Information in this section refers to components
relevant to both brake systems. Where the system
components are different they are referred to as ABS
or NON ABS
BRAKE SYSTEM NON ABS
Description
The servo assisted hydraulic braking system is the
dual line type, incorporating primary and secondary
hydraulic circuits.
NOTE: References made to primary or
secondary do not imply main service
brakes or emergency brakes but denote
hydraulic line identification.
The brake pedal is connected to a vacuum assisted
mechanical servo which in turn operates a tandem
master cylinder. The front disc brake calipers each
house four pistons, these pistons are fed by the
secondary hydraulic circuit. The rear disc brake
calipers each house two pistons, these are fed by the
primary hydraulic circuit via a pressure reducing valve.
A brake fluid level switch is incorporated into the
reservoir cap assembly, the switch will immediately
illuminate a warning light in the instrument binnacle
indicating low fluid or sudden fluid loss.
The brake fluid reservoir is divided, the section closest
to the servo feeds the primary circuit and the section
furthest from the servo feeds the secondary circuit.
Under normal operating conditions both the primary
and secondary circuits operate simultaneously on
brake pedal application. In the event of a failure in the
primary circuit the secondary circuit will still function. If
the secondary circuit fails the primary circuit will still
function. The brake pedal travel will be longer in the
event of a half system failure.If the servo should fail, both hydraulic circuits will still
function but would require greater pedal effort due to
the lack of vacuum assistance. The hand operated
parking brake acts on a brake drum at the rear of the
transfer gearbox and is completely independent of the
hydraulic circuits.
Hydraulic circuit non ABS
Key
A = Primary hydraulic circuit
B = Secondary hydraulic circuit
C = Pressure reducing valve

74WHEELS AND TYRES
6
REPAIR WHEELS
Remove
WARNING: The parking brake acts on
transmission, not rear wheels, and may
not hold vehicle when jacking unless
following procedure is used. If one front wheel
and one rear wheel is raised no vehicle holding or
braking effect is possible. Wheels MUST be
chocked in all circumstances.
Apply parking brake, select 'P' or a gear in main
gearbox and engage low gear in transfer box.
1.Loosen five wheel nuts.
2.Using a suitable trolley jack raise vehicle and
place on axle stands.
See INTRODUCTION,
Information, Jacking
3.Remove wheel nuts and carefully withdraw
wheel over studs.Refit
4.Ensure that retaining studs and nuts are clean.
5.Alloy wheels: Lightly coat wheel mounting spigot
face with a suitable anti-seize compound to
minimise possibility of adhesion between wheel
and spigot face.
6.Refit wheel taking care not to damage stud
threads. (Do not apply oil)
7.Fit wheel nuts and turn by hand for at least three
full threads before using any form of wheel
wrench.
8.Tighten nuts as much as possible using a
suitable wrench.
9.Lower vehicle and finally tighten nuts to correct
torque sequence shown. Alloy wheels and steel
wheels:
130Nm.

82AIR CONDITIONING
2
REPAIR PERIODIC MAINTENANCE
Routine servicing, apart from visual checks, is not
necessary. The visual inspections are as follows:
Condenser
With a water hose or air line, clean the fins of the
condenser to remove flies, leaves, etc. Check the pipe
connections for signs of oil leakage.
Compressor
Check pipe connections for signs of oil leakage.
Check flexible hoses for swelling. Examine the
compressor belt for tightness and condition.
Sight glass and Receiver/Drier
Examine the sight glass for bubbles with the system
operating. Check connections for leakage.
Evaporator
Examine the refrigeration connections at the unit. If
the system should develop a fault, or if erratic
operation is noticed,
See Fault diagnosis,
Refrigeration System Faults
RECEIVER DRIER
Service repair no - 82.17.01
Remove
CAUTION: If receiver/drier is to be refitted,
the ports must be blanked off immediately
on disconnection. Exposed life of unit is
only 15 minutes.
1.Disconnect battery negative lead.
2.Recover refrigerant from system.
See
Adjustment, Refrigerant Recovery Recycling
Recharging
WARNING: Wear eye and hand protection
when disconnecting components
containing refrigerant. Plug all exposed
connections immediately.
3.Remove 3 screws from bonnet locking platform
and remove radiator grille.
Automatic gearbox
4.Remove 4 bolts securing transmission oil cooler
to body.

AIR CONDITIONING
3
REPAIR 5.Disconnect 2 pipe unions from oil cooler. Use a
second wrench to support hose adapter.
6.Remove transmission oil cooler. Seal
connections.
All models
7.Remove bolt securing receiver/drier clamp.
WARNING: Wear eye and hand protection
when disconnecting components
containing refrigerant. Plug all exposed
connections immediately.
8.Move receiver/drier just sufficiently to gain
access to pipe flange bolts without distorting the
pipes.
9.Remove bolt securing each pipe flange to
receiver/drier.
10.Disengage pipe flanges and withdraw
receiver/drier from mounting bracket.
11.Remove 'O' ring from each pipe flange.Refit
12.Fit new 'O' ring to each pipe flange, lubricate
with refrigerant oil.
13.Position receiver/drier in mounting bracket with
inlet and outlet connections correctly aligned.
14.Engage pipe flanges, fit bolts in turn and tighten.
15.Fit clamp bolt.
Automatic gearbox
16.Refit transmission oil cooler. Use a second
wrench to support pipe unions.
17.Check gearbox fluid level, top-up if necessary.
All models
18.Evacuate and recharge air conditioning system.
See Adjustment, Refrigerant Recovery
Recycling Recharging
19.Perform a leak test on disturbed joints.
20.Carry out a functional check.

ELECTRICAL
7
REPAIR AUTOMATIC GEAR SELECTOR-PANEL BULB
Service repair no - 86.45.40
1.Disconnect battery negative lead.
2.Carefully prise quadrant finisher out of surround.
3.Carefully prise rear of surround away from
centre console.
4.Pull appropriate bulb holder from fitted position.
5.Remove bulb from holder.
Refit
6.Reverse removal procedureSTART INHIBIT / REVERSE LIGHT SWITCH
Service repair no - 44.15.19
Automatic gearbox
Remove
Reverse light switch is an integral part of start inhibitor
switch. It is located on left hand side of gearbox,
accessible from beneath vehicle.
1.Place vehicle on suitable ramp [hoist].
2.Disconnect battery negative lead.
3.Disconnect multi-plug.
4.Release clamp bolt, remove clamp.
5.Remove switch.
Refit
6.Fit a NEW 'O' ring to switch.
7.Reverse removal procedure.