gearbox LAND ROVER DISCOVERY 1999 Workshop Manual

AUTOMATIC GEARBOX - ZF4HP22 - 24
DESCRIPTION AND OPERATION 44-19
Fault effects and warning indications
Fault code,
OBD II
(TestBook)Fault description Effect Warning lamp
illumination
MIL Sport/
Manual
P0705
(14, 23)* Gear position switch,
incorrect outputsMaintains current gear in low range, limp
home mode in high range. Shift pressure to
maximum, harsh gear shifts/engagement.On On
P0721
(21)* Downshift safety
monitor prevented
downshift which would
have caused engine
overspeedMaintains current gear in low range, limp
home mode in high range. Shift pressure to
maximum, harsh gear shifts/engagement.On On
P0722
(22)* Torque converter
slippingMaintains current gear in low range, limp
home mode in high range. Shift pressure to
maximum, harsh gear shifts/engagement.On On
P0731
(29)* Ratio monitoring,
implausible 1st gear
ratioNo apparent effect On On
P0732
(30)* Ratio monitoring,
implausible 2nd gear
ratioNo apparent effect On Off
P0733
(31)* Ratio monitoring,
implausible 3rd gear
ratioNo apparent effect On Off
P0734
(32)* Ratio monitoring,
implausible 4th gear
ratioNo apparent effect On Off
P0741
(5)* Torque converter
lock-up clutch faultMay affect driveability. On Off
P0743
(7, 25)* Torque converter
lock-up solenoid (MV
3), open or short circuitLimp home mode in low and high ranges. Shift
pressure to maximum, harsh gear shifts/
engagement.On On
P0748
(10, 28)* Pressure regulating
solenoid (MV 4), open
or short circuitLimp home mode in low and high ranges. Shift
pressure to maximum, harsh gear shifts/
engagement.On On
P0753
(8, 26)* Shift solenoid (MV 1),
open or short circuitLimp home mode in low and high ranges. Shift
pressure to maximum, harsh gear shifts/
engagement.On On
P0758
(9, 27)* Shift solenoid (MV 2),
open or short circuitLimp home mode in low and high ranges. Shift
pressure to maximum, harsh gear shifts/
engagement.On On
P1562
(24)* Battery supply below
9V while engine
runningMaintains current gear in low range, limp
home mode in range. Shift pressure to
maximum, harsh gear shifts/engagement.Off On
P1601
(4)* ECU, EEPROM
checksumLimp home mode in low and high ranges. Shift
pressure to maximum, harsh gear shifts/
engagement.On On
P1606
(3)* EEPROM No apparent effect On†Off
P1606
(6)* Watchdog No apparent effect On On
P1612
(2)* Solenoid valves
power supply relay,
sticking closed or open
circuitLimp home mode in low and high ranges. Shift
pressure to maximum, harsh gear shifts/
engagement.On On

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-20 DESCRIPTION AND OPERATION
P1613
(1)* Solenoid valves
power supply relay,
sticking open or short
circuitLimp home mode in low and high ranges. Shift
pressure to maximum, harsh gear shifts/
engagement.On On
P1705
(39)Transmission high/low
range, implausible
inputNo apparent effect On Off
P1810
(12, 13)Sport/Manual warning
lamp circuit faultLamp fails bulb check or is permanently
illuminated. No effect on gearbox operation.On Off
P1841
(16)* CAN bus fault Maintains current gear in low range, limp
home mode in high range. Shift pressure to
maximum, harsh gear shifts/engagement.On On
P1842
(15)* CAN level monitoring Maintains current gear in low range, limp
home mode in range. Shift pressure to
maximum, harsh gear shifts/engagement.On On
P1843
(17)* CAN time-out
monitoringMaintains current gear in low range, limp
home mode in high range. Shift pressure to
maximum, harsh gear shifts/engagement.On On
P1884
(11)* CAN message:
Engine friction invalidNo apparent effect. On Off
P1884
(18)* CAN message:
Throttle position invalidSubstitute throttle angle of 50% adopted. No
kickdown. Operates in economy modes only.On On
P1884
(19)CAN message: Engine
temperature invalidSubstitute engine temperature derived from
other inputs. No apparent effect.On Off
P1884
(20)CAN message: Road
speed invalidNo apparent effect On Off
P1884
(33, 34)* CAN message:
Engine torque invalidSubstitute engine torque of derived from other
inputs. May affect shift quality.On Off
P1884
(35)* CAN message:
Engine speed invalidMaintains current gear in low range, limp
home mode in high range. Shift pressure to
maximum, harsh gear shifts/engagement.On On
P1884
(37)CAN message: Engine
air intake temperature
invalidNo apparent effect. On Off
P1844
(38)Altitude shift control
invalidNo reduced torque compensation, possible
reduction in performance/ driveability at
altitude or high ambient temperatures.On Off
* = Emissions (OBD II) relevant
†On = MIL illuminates immediately (in all other faults, MIL On = illuminates in the 2nd consecutive drive cycle if
fault still present)Fault code,
OBD II
(TestBook)Fault description Effect Warning lamp
illumination
MIL Sport/
Manual

AUTOMATIC GEARBOX - ZF4HP22 - 24
ADJUSTMENTS 44-21
ADJUST ME NTS
Cable - selector
$% 44.30.04
Check
1.Position vehicle on ramp.
2.Select position 'P'.
3.Loosen selector cable trunnion nut.
4.Ensure that gearbox selector lever is in 'P'
position, (fully forward) and tighten trunnion
nut.
5.Lower ramp.
Stall test
$% 44.30.13
Testing
1.Chock the wheels and fully apply the
handbrake.
2.Start the engine and run it until it reaches
normal operating temperature.
3.Apply the footbrake and select 'D'.
4.Fully depress the accelerator pedal and note
the tachometer reading. The figures should be
as given below. Do not carry out stall test for
longer than 10 seconds, and DO NOT repeat
until 30 minutes have elapsed.
lV8: 2200 to 2400 rev/min
lDiesel: 2600 to 2800 rev/min
5.A reading below 1300 rev/min indicates a
torque converter fault, ie stator free-wheel.
6.A reading between 1300 and 2200 rev/min (V8)
or between 1300 and 2600 rev/min (Diesel)
indicates reduced engine power.
7.A reading above 2400 rev/min (V8) or above
2800 rev/min (Diesel) indicates clutch slip.
NOTE: The figures quoted above were
measured at sea level with an ambient
temperature of 20
°C (68°F). At higher altitudes
or higher ambient temperatures, these figures
will be reduced.

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-23
REPAIRS
Cable and lever assembly - selector
$% 44.15.08
Remove
1.Remove centre console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - centre - automatic
models.
2.Raise vehicle on ramp.
3.Loosen selector cable trunnion nut.
4.Remove 'C' clip and release selector cable
from gearbox bracket.
5.Lower vehicle on ramp.
6.Remove sound deadener pad. 7.Remove 3 bolts securing selector lever bracket
to tunnel, remove selector lever.
8.Remove 'C' clip securing outer cable to
selector lever bracket.
9.Remove locking ring securing inner cable to
selector lever.
10.Release inner cable from selector lever,
release cable from grommet and remove cable
from selector lever bracket.
Refit
1.Position cable through grommet, align to
bracket and secure with 'C' clip.
2.Fit inner cable to selector lever and secure with
locking ring.
3.Feed selector cable through tunnel, align
bracket, fit and tighten bolts.
4.Fit sound deadener pad.
5.Fit centre console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - centre - automatic
models.
6.Position selector cable through trunnion and
gearbox bracket, secure with 'C' clip.
7.Adjust selector cable.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, ADJUSTMENTS, Cable - selector.

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-24 REPAIRS
Selector indicator
$% 44.15.10
Remove
1.Remove knob from gear lever.
2.Release selector panel from centre console.
3.Disconnect multiplug from selector panel and
remove panel. Refit
1.Position selector panel and connect multiplug.
2.Secure selector panel to console.
3.Fit gear lever knob.

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-25
Switch - starter inhibitor
$% 44.15.19
Remove
1. Diesel models: Remove exhaust front pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - Td5, REPAIRS, Pipe - front.
2.Move the selector lever to position 'P'.
3.Remove nut securing selector lever to gearbox
selector shaft and release lever.
4.Remove 2 bolts securing inhibitor switch to
gearbox.
5.Release multiplug from gearbox bracket.
6.Release inhibitor switch from selector shaft.
7.Disconnect switch multiplug and remove
switch. Refit
1.Ensure 'P' is selected by rotating selector shaft
fully clockwise.
2.Engage 'N' by rotating selector shaft 2 detents
anti-clockwise.
3.Position inhibitor switch to selector shaft,
connect multiplug and secure multiplug to
gearbox bracket.
4.Engage switch to selector shaft, and fit but do
not tighten retaining bolts.
5.Fit tool LRT-44-011 to selector shaft.
6.Insert setting pin into tool. Rotate switch until
setting pin engages with hole in switch as
shown and tighten bolts to 10 Nm (7 lbf.ft).
7.Remove setting tool LRT-44-011.
8.Position selector lever to selector shaft and
tighten nut to 26 Nm (19 lbf.ft).
9. Diesel models: Fit exhaust front pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - Td5, REPAIRS, Pipe - front.

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-26 REPAIRS
Seal - selector shaft
$% 44.15.34
Remove
1.Remove valve body assembly.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Valve body assembly.
2.Remove nut securing selector shaft lever and
release lever from shaft.
3.Remove 2 bolts securing gear selector switch
to gearbox and remove switch.
4.Drift out and discard selector quadrant roll pin.
Remove selector shaft.
5.Remove selector quadrant and connecting rod.
6.Remove oil seal taking care not to damage
seal housing. Refit
1.Clean shaft and seal housing.
2.Using a suitable adapter, fit new seal.
3.Position selector quadrant and connecting rod.
4.Position selector shaft and secure to quadrant
using new roll pin.
5.Fit valve body assembly.
+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Valve body assembly.

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-27
Gearbox - convertor and transfer
gearbox - Diesel
$% 44.20.04.99
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery earth lead.
3.Raise vehicle on a ramp.
4.Remove starter motor.

+ CHARGING AND STARTING,
REPAIRS, Starter motor - diesel.
5.Remove 2 upper bolts securing gearbox
housing to engine.
6.Remove bolt securing closing plate to gearbox
housing.
7.Remove exhaust front pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - Td5, REPAIRS, Pipe - front.
8.Remove 3 nuts securing intermediate silencer
to tail pipe.
9.Release and remove silencer from rubber
mountings. 10.Drain automatic gearbox oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
11.Drain transfer gearbox oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
12.Remove front propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
13.Remove rear propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.
14.Remove and discard 3 bolts securing torque
converter to drive plate.

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-28 REPAIRS
15.Remove handbrake drum retaining screw and
remove brake drum.
16.Remove 4 bolts from handbrake back plate,
release back plate and tie aside.
17. Models fitted with high/low shift interlock
solenoid: Release interlock solenoid multiplug
and disconnect multiplug from main harness.
18. Models fitted with high/low shift interlock
solenoid: Remove sleeve retaining rings and
remove sleeve from high/low selector cable.
19. If fitted Remove and discard clevis pin
securing differential lock selector cable to
transfer gearbox.20. If fitted Loosen locknuts securing differential
lock selector cable to differential lock selector
cable abutment bracket.
21. If fitted Release and remove differential lock
selector cable from differential lock selector
cable abutment bracket.
22.Remove clevis pin securing high/low ratio
selector cable to selector lever, remove 'C' clip
and remove outer cable from abutment
bracket.
23. Up to 03 Model Year - If fitted: Disconnect
from differential lock warning lamp switch and
multiplugs from high/low ratio switch and
neutral sensor.

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-29
24. 03 Model Year onwards - If fitted: Release
and disconnect both differential lock warning
lamp switch multiplugs from main harness.
25.Remove cable tie and multiplug from bracket
on transfer box.
26.Release transfer and automatic gearbox
breather pipes from clip at rear of cylinder
block.
27.Position gearbox support jack and secure tool
LRT-99-008A to support plate on jack. 28.Position a second support jack under engine
using a block between engine sump and jack
to prevent damage to sump.
29.Remove 4 bolts and nut, remove engine LH
rear mounting.
30.Remove 4 bolts and nut, remove engine RH
rear mounting.
31.Remove 2 bolts securing gearbox oil cooler
pipe clips to engine sump and alternator
mounting bracket.