LAND ROVER DISCOVERY 1995 Workshop Manual

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

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

ZF
5
SERVICE TOOLS
LRT-44-009 Adaptor pressure take off.
LST 502-1
LRT-44-010 Convertor lifting handles.
18G.1501

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

PROPELLER SHAFTS
1
REPAIR FRONT PROPELLER SHAFT
Service repair no - 47.15.02 - Front
Remove
1.Place vehicle over pit or on a ramp [hoist].
2.Remove nuts from each end of propeller shaft.
Remove shaft.
3.Scribe alignment marks on flanges at both ends
of propeller shaft to ensure correct refitting.
Service repair no - 47.15.11
Overhaul
4.Thoroughly examine universal joint for signs of
damage or wear. Replace if necessary.
5.Clean universal joint bearing cups and circlips.
CAUTION: To ensure correct assembly
and reduce possibility of imbalance.
Before removing propeller shaft joint. Mark
position of spider pin lubricator relative to journal
yoke ears.
6.Remove circlips, and grease nipple.
7.Tap yokes to eject bearing cups.
8.Remove bearing cups and spider.
9.Repeat instructions 4 to 7 for opposite end of
propeller shaft if necessary.
10.Clean yokes and bearing cup locations.
Assemble
11.Remove bearing cups from new spider.
12.Check all needle rollers are present and
positioned in bearing cups.
13.Ensure bearing cups are one-third full of
lubricant.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
14.Enter new spider with seals into yokes of sliding
member flange.
15.Partially insert one bearing cup into flange yoke
and enter spider trunnion into bearing cup.
16.Insert opposite bearing cup into flange yoke.
17.Press both cups into place.

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.