lock LAND ROVER DISCOVERY 1995 Workshop Manual

TRANSFER GEARBOX
3
REPAIR Refit
36.Select 'P' in main gearbox, with low range and
differential lock selected in transfer gearbox.
37.Secure transfer gearbox to adaptor plate on
lifting hoist.
38.Ensure joint faces of transfer and main
gearboxes are clean and guide studs 18G 1425
are fitted.
39.Raise hoist until transfer gearbox can be located
over guide studs to main gearbox. At the same
time locate high/low lower link to yoke.
40.Remove guide studs and secure transfer
gearbox to main gearbox.41.Complete refitting by reversing removal
procedure, noting the following important points.
42.After removal of adaptor plate from transfer
gearbox, clean threads of four bottom cover
bolts, coat threads with Loctite 290 and fit
together with spring washers. Tighten to
25Nm
43.Add correct grade of oil to transfer gearbox to oil
level plug hole.
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information,
Recommended Lubricants and Fluids
44.Check main gearbox oil level.
45.Check operation of parking brake and adjust as
necessary.
See SECTION 10, Maintenance,
Vehicle Interior

41TRANSFER GEARBOX
4
REPAIR SHIFTLOCK SOLENOID/NEUTRAL SWITCH
Service repair no - 41.10.63/64
This is sited on top of the transfer gearbox. Access to
the component is gained through the transmission
tunnel aperture.
Remove
1.Disconnect battery negative lead.
2.Remove centre console.
See CHASSIS AND
BODY, Repair, Centre Console
3.Remove rear passenger heater air ducts.
4.Remove insulation pad.
5.Remove four screws and remove main gear
lever assembly.
6.Drill out rivets and remove tunnel blanking plate.
7.Disconnect solenoid multiplug.
8.Remove four retaining bolts and remove shiftlock
solenoid cover.
9.Remove solenoid and spring washer.
10.Clean joint sealant from mating faces.
KEY
1. Gearlever
2. Transmission tunnel aperture
3. Transfer gearbox
4. Bolt
5. Switch
6. Solenoid
7. Electrical connectionsRefit
1.Apply Hylosil or equivalent sealant to mating
faces.
2.Ensure solenoid plug lead is located in cover
recess.
3.Reverse removal procedure.
4.Fit four solenoid bolts. Tighten to
9Nm.
Neutral switch, audible alarm
1.Disconnect neutral switch electrical plug.
2.Remove neutral switch from transfer box.
Refit
3.Apply Hylomar PL32/L20 or SL500 sealant to
neutral switch.
4.Reverse removal procedure.
5.Switch - Tighten to
25Nm.

TRANSFER GEARBOX
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
LT230T Transfer gearbox
Pinch bolt - operating arm to crank arm 9......................................................
End cover gear change housing 9.................................................................
Bottom cover to transfer case 25....................................................................
Front output housing to transfer case 25........................................................
Cross shaft housing to front output housing 25...............................................
Gear change housing 25.................................................................................
Pivot shaft to link arm 25.................................................................................
Connecting rod to adjustable clevis 25...........................................................
Anti-rotation plate intermediate shaft 25.........................................................
Front output housing cover 25........................................................................
Pivot bracket to extension housing 25............................................................
Finger housing to front output housing 25......................................................
Bearing housing to transfer case 25...............................................................
Brake drum to coupling flange 25...................................................................
Bearing housing cover to transfer gearbox 45................................................
Rear output speedometer housing to transfer gearbox 45..............................
Selector finger to cross shaft high/low 25.......................................................
Selector fork, high/low to shaft 25...................................................................
Transmission brake to speedometer housing 72............................................
Gate plate to grommet plate 9.......................................................................
Gearbox to transfer case 45...........................................................................
Oil drain plug 30..............................................................................................
Oil filler/level plug 30.......................................................................................
Differential case (front to rear) 60...................................................................
Output flanges 162...........................................................................................
Differential case rear stake nut 72..................................................................
Transfer breather 15.......................................................................................
Transfer box front drive flange to drive shaft 45..............................................
Transfer box rear drive flange to drive shaft 45..............................................
Transfer gearbox mounting brackets to chassis 30........................................
Mounting brackets to transfer gearbox 55......................................................
Mounting rubbers to mounting brackets 21.....................................................
Shiftlock
Shiftlock screws 9..........................................................................................
Neutral switch 25............................................................................................

41TRANSFER GEARBOX
2
SPECIFICATIONS, TORQUE LT230T TRANSFER GEARBOX DATA
High range gear end - float 0,05 to 0,15 mm..............................................
Front differential bearing pre - load 0.56 to 1.69 Nm..................................
Input gear bearing pre - load 0.56 to 2.25 Nm............................................
Intermediate shaft bearing pre - load 0.56 to 1.69 Nm...............................
JOINT SEALANT
Joint faces use BLS. 22SE03 TYPE 2.................................................................
Shiftlock solenoid cover HYLOSIL RTV...................................................
Neutral switch HYLOMAR...................................................................

ZF
1
DESCRIPTION AND OPERATION DESCRIPTION
The automatic transmission is specially tailored version of the ZF4 HP22, used by many manufacturer's of high
performance vehicles.
A three element torque converter delivers the power to a four speed epicyclic transmission. First, second and third
gears are reduction ratios but fourth is an overdrive gear for high speed cruising. A direct drive clutch, integral with
the torque converter operates to engage fourth gear.
The gear selector has seven positions as follows:
P = Park provides a mechanical lock on the output shaft.
R = Reverse gear.
N = Neutral.
D = Provides a 1st gear start and automatic shifts 1-2-3-4-3-2-1.
3 = Provides a 1st gear start and automatic shifts 1-2-3-2-1.
2 = Provides a 1st gear start and automatic shifts 1-2-1 or 3-2-1.
1 = Provides a 1st gear start with no up shifts, or 3-2-1.
All automatic shifts are automatically controlled by the valve block and an hydraulic governor driven by the output
shaft.

44AUTOMATIC GEARBOX
2
DESCRIPTION AND OPERATION Power flow
1st gear D selected
With D selected 1st gear engaged, clutches 4 and 11 are operative. The front planet gear carrier of gear set 9 is
locked against the housing through freewheel 15 when the engine is pulling but freewheels when the vehicle is
coasting. Epicyclic gear set 10 rotates as a solid unit with the front planet gear carrier. In selector position 1 with
1st gear engaged, clutch 8 operates to prevent the loss of drive on the overrun through freewheel 15, to provide
engine braking.
2nd gear D selected
Clutches 4, 6, 7 and 11 are engaged. Freewheel 15 overruns, the hollow shaft with the sun wheel of epicyclic gear
set 9 is locked. Epicyclic gear set 10 also rotates as a solid unit.

ZF
3
DESCRIPTION AND OPERATION 3rd gear D selected
Clutches 4, 5, 7 and 11 are engaged. Freewheel 15 and 16 are overrun. Epicyclic gear set 9 and 10 rotate as a
solid unit at a ratio of 1:1.
4th gear D selected
Clutches 4, 5, 7 and 12 are engaged. Freewheel 14, 15 and 16 are overrun. Epicyclic gear set 9 rotates as a solid
unit. The hollow shaft with the sun wheel of epicyclic gear set 10 is locked.
Above a predetermined road speed, clutch 2 locks the gearbox power input direct to the engine, by-passing the
torque converter.

44AUTOMATIC GEARBOX
4
DESCRIPTION AND OPERATION Reverse gear
Clutches 5, 8 and 11 are engaged. Since the front planet gear carrier of epicyclic gear set 9 is locked, the direction
of output-shaft rotation is reversed. Epicyclic gear set 10 also rotates as a solid block.

44AUTOMATIC GEARBOX
10
FAULT DIAGNOSIS FAULT SYMPTOMS
SYMPTOM 1 - Intermittent drive and high pitched
noise
FAULT - Low fluid level or restricted filter
SYMPTOM 2 - No drive in reverse
Select 'D'
ú No drive
FAULT - Continue with Symptom 3
ú Drives forward
FAULT - Reverse gear interlock valve
seized
Select '1'
ú No engine braking
FAULT - Clutch brake 3
SYMPTOM 3 - No drive from rest with 'D' selected
Select '1'
ú Vehicle drives
FAULT - No 2 freewheel
ú No drive
Carry out main line pressure check
ú Normal pressure
FAULT - Clutch A
ú No pressure
FAULT - Blocked filter or pump failure
ú Low pressure
FAULT - Restricted filter or sticking primary
regulator
SYMPTOM 4 - Slip in all forward gears
Carry out main line pressure check
ú No pressure
FAULT - Blocked filter or pump failure
ú Low pressure
FAULT - Restricted filter or sticking primary
regulator
ú Normal pressure
FAULT - Clutch 'A'SYMPTOM 5 - Harsh engagement 'N' to 'D'
Check engine idle speed
Carry out main line pressure check
ú High pressure
FAULT - Primary regulator stuck
ú Normal pressure
FAULT - Clutch 'A' or damper for clutch'A'
SYMPTOM 6 - Fierce shift or flare 1st to 2nd shift
Check engine idle speed
Carry out mainline pressure check
ú High pressure
FAULT - Continue with symptom 5
ú Normal pressure
FAULT - Modulator valve or dampers for
clutch brake CB1 and/or clutch brake CB2
FAULT - Clutch brake CB1 and/or clutch
brake CB2
SYMPTOM 7 - Fierce shift or flare 2nd to 3rd
Carry out mainline pressure check
ú High pressure
FAULT - Continue with symptom 5
ú Normal pressure
FAULT - Modulator valve or clutch 'B'
damper
FAULT - Clutch 'B'
SYMPTOM 8 - No 3rd gear
FAULT - 2-3 shift valve
FAULT - Clutch 'B'
SYMPTOM 9 - No 4th gear 'D' selected
FAULT - 4th to 3rd downshift valve stuck or
3rd to 4th upshift valve stuck
FAULT - Clutch brake 4

ZF
11
FAULT DIAGNOSIS SYMPTOM 10 - None or harsh engagement of
direct drive clutch
NOTE: The direct drive clutch will only
engage if 4th gear is engaged at 40 to 45
mph.
Carry out road test pressure check with gauge
connected to torque converter.
ú Normal pressure
FAULT - Failed direct drive clutch
ú Pressures correct but remains high
FAULTS POSSIBLE -
Direct drive clutch and torque converter
control valve stuck
Hysteresis valve stuck
Direct drive clutch control valve stuck
SYMPTOM 11 - Direct drive clutch shift point
incorrect or at low speed
NOTE: Direct drive clutch engagement at
low speed will cause vibration in the
torque converter
Carry out mainline and torque converter pressure
check
ú Normal pressure
FAULT - Governor valve sticking
ú Low or incorrect pressure
FAULTS POSSIBLE -
Direct drive clutch and torque converter
control valve sticking.
Hysteresis valve stuck.
Direct drive clutch control valve stuck.
SYMPTOM 12 - Drives in 'D' but immediately
upshifts to 3rd
FAULT - 2nd to 3rd shift valve stuck.
SYMPTOM 13 - With 'D' selected vehicle starts in
2nd
FAULTS POSSIBLE -
1st and 2nd shift valve stuck.
Governor sleeve sticking.
SYMPTOM 14 - With 'D' selected vehicle starts in
3rd
FAULTS POSSIBLE -
1st to 2nd and 2nd to 3rd shift valves stuck.
Governor sleeve sticking.SYMPTOM 15 - No kickdown 4th to 3rd
FAULT - 4th to 3rd kickdown valve stuck.
SYMPTOM 16 - Upshifts/downshifts and kickdown
shifts at incorrect road speeds
Check throttle kickdown cable adjustment
Carry out main line pressure check
ú Normal pressure
FAULT - Governor valve sticking
ú Incorrect pressure
FAULTS POSSIBLE -
Incorrect throttle valve adjustment
Primary regulator sticking
SYMPTOM 17 - No upshifts at light throttle
FAULTS POSSIBLE
Governor valve sticking
Shift valves sticking
SYMPTOM 18 - No engine braking '3' selected 3rd
gear
FAULT - Clutch 'C'
SYMPTOM 19 - Delayed or no downshift occurs
when making a manual selection from '3' to '2'
FAULTS POSSIBLE -
2nd and 3rd upshift valve sticking.
Governor valve sticking.
'2' Position interlock valve sticking.
SYMPTOM 20 - At speeds below 28 mph when
making a manual selection from '2' to '1',
downshift is delayed or does not occur
FAULTS POSSIBLE -
Governor sticking.
1st to 2nd shift valve sticking.
'1' Position interlock valve sticking.
SYMPTOM 21 - '1' Selected 1st gear no engine
braking
FAULT - Clutch brake 3
SYMPTOM 22 - '2' Selected 2nd gear no engine
braking
FAULT - Clutch brake 1
SYMPTOM 23 - Vehicle drives forward in 'N'
FAULT - Clutch 'A' stuck