recommended oil LAND ROVER DISCOVERY 1995 Owner's Manual

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

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

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

54FRONT AXLE AND FINAL DRIVE
4
OVERHAUL 12.Examine all components in particular inner and
outer track, cage balls and bearing surfaces for
damage and excessive wear.
13.Maximum acceptable end-float on assembled
joint 0,64mm. Renew if worn or damaged.
Lubricate with a recommended oil during
assembly.
Fit constant velocity joint to axle
14.Fit collar and a new circlip.
15.Engage constant velocity joint on axle shaft
splines and using a soft mallet, drive joint in fully.
Renew stub axle,thrust ring, oil seal and bearing
16.Drill and chisel off thrust ring taking care to avoid
damaging stub axle.
17.Remove bearing and oil seal using special tool
LRT-37-004 and slide hammer LRT-99-004.
Ensure lip of tool locates behind bearing to to
drive it out.
18.Repeat instruction for removal of oil seal.
19.Lubricate seal and lip with EP90 oil and with
cavity side leading press in a new oil seal using
special tool LRT-54-004.
20.Using special tool LRT-54-005, fit bearing with
its part number visible when fitted, and flush with
end face of stub axle.
21.Press fit a new thrust ring onto stub axle.

54FRONT AXLE AND FINAL DRIVE
6
OVERHAUL Swivel assembly components
1. Swivel pin housing
2. Top swivel pin and brake hose bracket
3. Upper and lower swivel pin bearings
4. Shim
5. Retaining plate and washer
6. Oil seal
7. Joint washer
8. Swivel bearing housing
9. Joint washer
10. Lower swivel pin
11. Mudshield bracket
12. Swivel housing inner oil sealCheck and adjust preload on bearings
NOTE: Swivel housing oil seal and axle
should not be fitted.
47.Attach a spring balance to ball joint bore and pull
balance to determine effort required to turn
swivel pin housing.
Resistance, once initial inertia has been
overcome, should be1.16 to 1.46 kg.Adjust by
removing or adding shims to top swivel pin.
48.When setting is correct remove top swivel bolts,
apply Loctite 270 or equivalent. Refit to
78 Nm,
and bend over lock tabs.
49.Apply recommended grease between lips of
swivel oil seal.
50.Fit oil seal, joint washer and retaining plate with
seven bolts and spring washers to
11 Nm.
51.Fit tie rod and drag link and secure with new
cotter pins. Tighten to
40 Nm.
52.Fit brake disc shield.
53.Loosely fit lock stop bolt and nut.
54.Apply a recommended grease between lips of
swivel housing oil seal.
55.Secure oil seal with retaining plate and securing
bolts. Tighten to
11 Nm.
56.Fit track-rod and drag link and secure with new
cotter pins.
57.Loosely fit lock stop bolt for later adjustment.
58.Fit brake disc shield.

54FRONT AXLE AND FINAL DRIVE
8
OVERHAUL Remove constant velocity joint from axle shaft
7.Hold axle shaft firmly in a soft jawed vice.
8.Using a soft mallet drive constant velocity joint
from shaft.
9.Remove circlip and collar from axle shaft.
Constant velocity joint
10.Mark positions of constant velocity joint, inner
and outer race and cage for reassembly.
11.Swivel cage and inner race to remove balls.
12.Examine all components in particular inner and
outer track, cage balls and bearing surfaces for
damage and excessive wear.
13.Maximum acceptable end-float on assembled
joint 0,64mm. Renew if worn or damaged.
Lubricate with a recommended oil during
assembly.
Fit constant velocity joint to axle
14.Fit collar and a new circlip.
15.Engage constant velocity joint on axle shaft
splines and using a soft mallet, drive joint in fully.
Renew stub axle,thrust ring, oil seal and bearing
16.Drill and chisel off thrust ring taking care to avoid
damaging stub axle.
17.Remove bearing and oil seal using special tool
LRT-37-004 and slide hammer LRT-99-004.
Ensure lip of tool locates behind bearing to to
drive it out.
18.Repeat instruction for removal of oil seal.