oil LAND ROVER DISCOVERY 1995 Workshop Manual

ZF
1
FAULT DIAGNOSIS ZF AUTOMATIC GEARBOX
Before referring to fault symptoms, carry out initial
static checks first:
INITIAL STATIC CHECKS
Check start positions 'P' & 'N' only........................................................
Reverse lights 'R' only..................................................................
Gear engagements N-D,N-3,N-2,N-1,N-R..........................................................
Full throttle Engine switched off, check full travel at engine and at.......................................................................
pedal.
Oil level 'N' selected, engine running at normal running............................................................................
temperature.
Pressure test
2000 rev/min 10±0.3 bar, 150±5 lbf/in
2....................................................................
Idle pressure 6.9±0.3 bar, 100±5 lbf/in2at 665 to 735 rev/min. ....................................................................
To fit pressure gauge
Service tools:
See Service tools, Automatic
Gearbox
0 to 20 bar, 0 to 300 lbf/in2Pressure gauge.
Flexible hose adaptor.
1.Site vehicle on a ramp [hoist].
2.From under gearbox, remove socket head plug
(located 10cm from oil pipe) Fit hose adaptor
LST502-1.
3.Fit hose to adaptor.
4.Fit gauge 18G502A to hose and route into
vehicle, ensuring hose is clear of rotating parts
and exhaust pipes.
5.Carry out road test.
See Road Test Procedure
Remove pressure gauge
6.Reverse removal procedure.

44AUTOMATIC GEARBOX
2
REPAIR 1.Site vehicle on a four post ramp [hoist].
2.Disconnect battery negative lead.
3.Remove fan cowl securing screws and release
cowl from radiator.
4.Loosen securing clip and disconnect air flow
hose from plenum chamber.
5.Disconnect stepper motor hose from top of
plenum chamber.
6.Disconnect kickdown cable from throttle linkage
and release from clipping.7.Release two gearbox breather pipes from clip
located on lifting eye at rear of right hand
cylinder head.
8.Remove dipstick from main gearbox oil filler
tube.
9.Working inside vehicle detach transfer gear lever
gaiter from console, unscrew knob and withdraw
gaiter and knob.
10.Raise vehicle on ramp [hoist].
11.Remove drain plugs and drain oil from transfer
gearbox and main gearbox. Refit plugs.
12.Detach heat shield at front exhaust pipe to
manifold.
13.Disconnect electrics to Lambda sensors.
14.Remove catalytic converter assembly.
15.Remove chassis cross-member from under
gearbox.16.Remove heat shield from speedometer cable at
transfer gearbox.
17.Remove clamp and disconnect speedometer
cable from transfer gearbox. Tie cable to one
side.
18.Mark for reassembly propeller shaft to transfer
gearbox mating flanges.

ZF
3
REPAIR 19.Disconnect rear propeller shaft to output flange,
and tie to one side.
20.Repeat instructions 18 and 19 on front propeller
shaft to main gearbox.
21.Remove bolts retaining silencer front and rear
securing brackets and tie silencer to one side.
22.Disconnect oil cooler feed and return pipes from
bottom and side of main gearbox.
23.Release cooler pipes from clamp at engine sump
and remove distance piece.
24.Blank pipe ends and unions.
25.Move oil cooler pipes clear of transmission and
tie aside.
26.Disconnect selector cable from operating lever.
27.Disconnect inhibitor switch at multiplug.
28.Attach adaptor plate to hoist.
29.Remove two bolts from transfer gearbox rear
cover.
30.Raise hoist to align adaptor plate with transfer
gearbox and transmission. Secure to transfer
gearbox at rear cover with two bolts removed.
31.Adjust hoist to take weight of transmission.
32.Remove nuts and bolts securing right transfer
gearbox mounting bracket to chassis.
33.Repeat for the left mounting bracket. Removal of
these fixings will also free speedometer
transducer bracket
34.Remove right side mounting bracket to flexible
mounting rubber retaining nut.
35.Lower hoist until rear brake drum clears
passenger footwell. Check engine does not
crush any components while lowering.
36.Remove clip and clevis pin from park brake
lever.
37.Remove clip securing outer brake cable
38.The park brake cable is now free.
39.Disconnect leads from transfer gearbox
temperature sensor and differential lock warning
light switch.
40.Remove ties securing breather pipes to harness.
41.Remove bell housing access plate complete with
gasket.
42.Rotate engine, using crankshaft pulley, until two
access holes are visible in drive plate/ring gear
assembly through bell housing bottom cover
opening.
43.Identify an access hole and bolt hole to aid
reassembly.
44.Remove bolts securing drive plate to convertor
through access holes.
45.Rotate crankshaft half turn to access and
remove remaining bolts.
46.Disconnect oil dipstick tube at main gearbox.
47.Remove bolt at bell housing and detach dipstick
tube. Blank pipe end and union.
48.Position hoist jack channel under engine and
support using a wooden block.
49.Remove bell housing to engine securing bolts,
also detach harness bracket from bell housing.
50.Ease transmission rearwards to allow access to
secure torque converter in bell housing.
51.Lower hoist and complete removal of
transmission.
Refit
52.Ensure torque converter is retained in bell
housing.
53.Secure transmission to adaptor plate on lifting
hoist.
54.Raise hoist and locate transmission with engine.
55.Remove torque converter retainer.
56.Complete attachment of transmission to engine
and fit bell housing bolts. Fit the dipstick tube
bracket and harness bracket to their respective
bolts.
57.Complete refitting by reversing removal
procedure. Note the following important points.
58.Drive plate to torque converter bolts are to be
coated with Loctite 290 prior to assembly.
59.Refill transfer and main gearboxes with correct
grade oil.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
60.Check operation of parking brake and adjust as
necessary.
See SECTION 10, Maintenance,
Vehicle Interior

44AUTOMATIC GEARBOX
6
REPAIR 13.Remove starter.
14.Working through starter aperture note position of
torque converter flexible drive plate to facilitate
refitting.
15.Remove the four torque convertor to flexible
drive securing bolts, rotating engine to gain
access to each individual bolt.
16.Raise vehicle on four post ramp [hoist].
17.Drain lubrication oil from transfer and main
gearboxes.
18.Disconnect speedometer cable from transfer
gearbox and disconnect associated clipping.
19.Remove rear propeller shaft.
See PROPELLER
SHAFTS, Overhaul, Flexible Coupling
20.Disconnect front propeller shaft at transfer
gearbox and tie to one side.
21.Remove exhaust front pipe.
22.Remove bolts securing front and centre silencer
mounting brackets and tie silencer to one side.
23.Disconnect oil cooler pipes from gearbox.
24.Blank off pipes and union connections.
25.Remove bolt securing retaining bracket to sump
and move cooler pipes aside.
26.Disconnect selector cable from lever on side of
gearbox.
27.Disconnect inhibitor switch multi-plug.
28.Disconnect park brake cable from linkage to park
brake lever.
29.Disconnect electrical connections from
differential lock switch on transfer gearbox.
30.Remove two lower bolts from transfer gearbox
input bearing support plate.
31.Assemble approved support cradle to
transmission hoist.32.Raise hoist and secure cradle to transfer
gearbox input bearing support plate using bolts
removed.
33.Disconnect gearbox mounting brackets from
chassis cross member.
34.Remove chassis cross member.
35.Lower transmission sufficiently to allow access
to items attached to top of gearbox.
36.Remove left hand gearbox mounting bracket
assembly.
37.Remove ties from breather pipes and harness.
38.Remove nut securing gearbox oil filler/dip stick
tube to bell housing.
39.Release union nut at gearbox sump and remove
filler/dipstick tube. Fit blanking plugs.
40.Support engine using a wooden block with a
suitable ramp [hoist] jack.
41.Remove nut securing kick down cable bracket to
bell housing.
42.Remove two bolts securing top of bell housing to
flywheel housing.
43.Remove nuts securing bell housing to flywheel
housing and withdraw transmission assembly
from engine.
44.Fit a suitable torque converter retaining strap to
the bell housing.
45.Remove hoist and transmission from under
vehicle.
46.Fit lifting eyes to transmission.
47.Using suitable chains and lifting tackle take
weight of transmission assembly.
48.Remove bolts securing transmission cradle to
transfer box and withdraw hoist complete with
cradle.
49.Refit bolts to cover plate.

ZF
7
REPAIR Accessories removal/fitting
If fitting a replacement transmission assembly to the
vehicle, remove the following items from the existing
assembly and fit to the replacement.
CAUTION: It is important to remove the
spacer from the extension shaft and fit
onto the replacement unit.
50.Breather pipe union and washers from main
gearbox.
51.Breather pipe, union and washers from transfer
gearbox.
52.Main gearbox selector lever.
53.RH mounting bracket assembly.
54.Oil cooler pipe unions.
55.Fit blanks to all apertures where unions have
been removed and blank off pipe ends.
Refit
1.Fit transmission to cradle and hoist.
2.Locate hoist under vehicle and remove torque
convertor retaining strap.
3.Ensure low range gear is engaged.
4.Apply approved sealant to bell housing face.
5.Carefully raise assembly, align bell housing with
flywheel housing and bring mating faces
together.
6.Fit nuts and bolts to secure transmission to
engine.
7.Locate electrical wiring and breather pipes to
position.
8.Secure kick down cable clip to bell housing.
9.Raise hoist sufficiently to take weight.
10.Remove block and jack from engine sump.
11.Fit filler/dipstick tube to gearbox sump and
secure bracket to bell housing.
12.Apply Loctite to torque convertor bolts
13.Working through starter aperture refit the four
torque convertor to flexible drive securing bolts,
rotating crankshaft to gain access to bolt
locations.
14.Refit starter and heatshield.
15.Secure breather pipes and harness with ties.
16.Fit left hand mounting bracket assembly to
gearbox.
17.Raise transmission and support with a suitable
ramp [hoist] jack.
18.Remove two bolts securing transmission to
cradle, lower hoist and remove from under
vehicle.
19.Apply Loctite to above bolts and fit to transfer
gearbox input bearing support plate.
20.Fit chassis cross member.21.Secure gearbox mounting brackets to chassis
cross member.
22.Remove ramp [hoist] jack.
23.Connect electrical leads to differential lock
switch.
24.Connect inhibitor switch multi-plug.
25.Connect selector cable to lever on side of
gearbox.
26.Connect oil cooler pipes to gearbox and secure
retaining bracket to gearbox sump.
27.Secure silencer to chassis and refit exhaust front
pipe.
28.Refit front propeller shaft to transfer gearbox.
29.Refit rear propeller shaft.
See PROPELLER
SHAFTS, Overhaul, Flexible Coupling
30.Connect speedometer cable to transfer gearbox.
31.Refill transfer gearbox with correct grade of
lubricating oil.
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information,
Recommended Lubricants and Fluids
32.Lower ramp [hoist] to ground level.
33.Reconnect turbo-charger hose to inter-cooler.
34.Reconnect top hose to radiator.
35.Refill cooling system with correct mixture of
coolant.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
36.Reconnect kick down cable to fuel injection
pump.
37.Secure breather pipe clip to rear of cylinder
head.
38.Engage harness with clips along top of
bulkhead.
39.On left hand drive vehicles only, connect
multi-plug to top of brake fluid reservoir.
40.Refit insulation pad to rocker cover and inlet
manifold, secure with oil filler cap.
41.Refit gaiter and knob to transfer gear lever.
42.Select high range gear.
43.Reconnect battery terminals.
44.Refill main gearbox with correct grade of
lubricating oil.
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information,
Recommended Lubricants and Fluids

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