gearbox LAND ROVER DISCOVERY 1999 Owner's Manual

LIFTING AND TOWING
08-1
LIFTING AND TOWING
LIFTING
The following instructions must be carried out before
raising the vehicle off the ground.
lUse a solid level ground surface.
lApply hand brake.
lSelect 'P' (Automatic gearbox) or 1st gear
(Manual gearbox) in main gearbox.
lSelect Low range in transfer gearbox.
To avoid damage occurring to the under body
components of the vehicle the following jacking
procedures must be adhered to.
DO NOT POSITION JACKS OR AXLE STANDS
UNDER THE FOLLOWING COMPONENTS:
lBody structure
lBumpers
lFuel lines
lBrake lines
lFront radius arms
lPanhard rod
lSteering linkage
lRear trailing arms
lFuel tank
lEngine sump
lGearbox bell housing
Vehicle jack
The jack provided with the vehicle is only intended for
use in an emergency, for changing a tyre. DO NOT
use the jack for any other purpose. Refer to Owner's
Handbook for vehicle jack location points and
procedure. Never work under a vehicle supported
solely by the vehicle jack.
Hydraulic jack
A hydraulic jack with a minimum 1500 kg, 3,300 lbs
load capacity must be used. Do not commence
work on the underside of the vehicle until
suitable axle stands have been positioned under
the axle.
WARNING: Always chock the wheels when
jacking. The hand brake acts on the
transmission, not the rear wheels, and may be
ineffective when the wheels are off the ground.Raising and supporting the vehicle
Position cup of hydraulic arm under differential
casing (1).The differential casing is not central to
the axle. Care should be taken when raising the
front road wheels off the ground as the rear axle
has less sway stiffness.
Raise vehicle to enable an axle stand to be installed
under left hand axle tube (2).
Position an axle stand under right hand axle tube (4).
Carefully lower jack until vehicle sits securely on both
axle stands, remove jack.
Alternatively, the axle stands can be positioned
under the chassis longitudinals at the front and/or
rear of the vehicle.

LIFTING AND TOWING
08-2
Before commencing work on underside of vehicle re-
check security of vehicle on stands.
WARNING: Always chock the wheels when
jacking. The hand brake acts on the the
transmission, not the rear wheels, and may be
ineffective when the wheels are off the ground.
Reverse procedure when removing vehicle from
stands.
Hydraulic ramps
Use only a 'drive on' type ramp which supports a
vehicle by it's own road wheels. If a 'wheel free'
condition is required, use a 'drive on' ramp
incorporating a 'wheel free' system that supports
under axle casings. Alternatively, place vehicle on a
firm, flat floor and support on axle stands.
TOWING
Towing
The vehicle has permanent four wheel drive. The
following towing instructions must be adhered
to:
Towing on 4 wheels with driver
Turn ignition key to position '1' to release steering
lock.
Select neutral in main gearbox and transfer gearbox.
Secure tow rope, chain or cable to towing eye.
Release the handbrake.
The brake servo and power assisted steering
system will not be functional without the engine
running. Greater pedal pressure will be required
to apply the brakes, the steering system will
require greater effort to turn the front road
wheels. The vehicle tow connection should be
used only in normal road conditions, 'snatch'
recovery should be avoided.
Suspended tow
To prevent vehicle damage, front or rear
propeller shaft MUST BE removed, dependent
upon which axle is being trailed.
Mark propeller shaft drive flanges at transfer box and
axles with identification lines to enable the propeller
shaft to be refitted in its original position.

LIFTING AND TOWING
08-4
TRANSPORTING
Transporting by trailer
Front lashing eyes
Rear lashing eyesLashing eyes are provided on the chassis
longitudinals, at the front (behind the front wheels)
and at the rear (behind the rear wheels).
DO NOT secure lashing hooks or trailer fixings to
any other part of the vehicle.
Position the vehicle on the trailer and apply the
handbrake. Select neutral in the manual gearbox ('N'
on automatic gearbox). Selecting 'N' will prevent
damage to the parking pawl in the automatic
gearbox.

CAPACITIES, FLUIDS, LUBRICANTS AND SEALANTS
09-1
CAPACITIES, FLUIDS, LUBRICANTS AND SEALANTS
Capacities
The following capacities are only an approximation of
the amount of fluid required to fill the respective
system.
Capacities - UK EURO ROWCapacities - NAS
Refrigerant - A/C system
Component Metric Units
Fuel tank 95 litres
Engine - Td5:
⇒ Engine oil and filter change 7.2 litres
⇒ Fill from dry 8.2 litres
Engine - V8 with oil cooler:
⇒Engine oil and filter change 6.27 litres
⇒Engine oil refill from dry: 7 litres
Engine - V8 without oil cooler:
⇒Engine oil and filter change 5.8 litres
⇒ Engine oil refill from dry 6.5 litres
Manual gearbox without oil cooler:
⇒ Refill 2.3 litres
⇒ Fill from dry 2.6 litres
Manual gearbox with oil cooler:
⇒ Refill 2.8 litres
⇒ Fill from dry 3.1 litres
Automatic gearbox fill from dry 9.7 litres
Transfer box:
⇒ Refill 2.0 litres
⇒ Fill from dry 2.3 litres
Front and rear axle:
⇒ Refill 1.6 litres
⇒ Fill from dry 1.7 litres
Cooling system - Td5 Engine:
⇒ Refill 8 litres
⇒ Fill from dry 13 litres
Cooling system - V8 Engine:
⇒ Refill 12 litres
⇒ Fill from dry 13 litres
Component US Units
Fuel tank 25.5 gal
Engine - V8 with oil cooler:
⇒ Engine oil and filter change 6.6 qt
⇒ Engine oil refill from dry 7.4 qt
Engine - V8 without oil cooler:
⇒ Engine oil and filter change 6.1 qt
⇒ Engine oil refill from dry 6.9 qt
Automatic gearbox fill from dry
19.7 pt
Transfer box:
⇒ Refill 4.1 pt
⇒ Fill from dry 4.8 pt
Front and rear axle:
⇒ Refill 3.4 pt
⇒ Fill from dry 3.6 pt
Cooling system - V8 Engine:
⇒ Refill 24.2 pt
⇒ Fill from dry 26.2 pt
⇒Front A/C 700 ± 25 g
⇒Front/rear A/C 900 ± 25 g

CAPACITIES, FLUIDS, LUBRICANTS AND SEALANTS
09-4
Gearbox oil
Manual Gearbox: Use Texaco MTF 94 oil for refill
and topping-up.
Automatic Gearbox: Use Texamatic 9226, ATF
Dexron 11D or Dexron 111 for refill and topping-up
Transfer box
Use Texaco Multi-Gear 75W/90R or oil meeting
specification API GL5.
Front and rear axles
Use Texaco Multi-Gear 75W/90R.
Air Conditioning
Use lubricating oil Nippon Denso ND-8.
General Greasing
Use Multipurpose Lithium Base Grease N.L.G.I.
consistency No. 2.
Bonnet latch
Lubricate cable and latch with oil.
Sealants
The following table lists those sealants which are
used during repair / overhaul procedures covered in
this manual; it is essential that the sealant specified
for a particular procedure is used at all times.
Component Application Land Rover
Part No.
Td5 Engine Timing chain fixed
guide Allen screwSTC 50552
Td5 Engine Camshaft cover
gasket joint lineSTC 50550
Td5 Engine Oil pick-up strainer
Torx screwsSTC 50552
Td5 Engine Oil pump drive
sprocket retaining
boltSTC 50552
Td5 Engine Timing chain cover,
crankshaft rear oil
seal and sump
gasket joint linesSTC 50550
Td5 Engine Oil pressure relief
valve plugSTC 50552
Td5 Engine Camshaft carrier to
cylinder headSTC 4600
Td5 Engine Timing cover STC 50550
V8 Engine Sump gasket to
cylinder blockSTC 50550
V8 Engine 'V' grooves at end
of cylinder head -
Inlet manifold
gasketSTC 50550
V8 Engine Cruciform seal
endsSTC 50550
V8 Engine Dipstick tube STC 50554
V8 Engine Timing cover bolts STC 50552
Engine
Management
System - V8Engine coolant
temperature (ECT)
sensor threadsSTC 50552
Manifolds and
Exhaust
System - V8'V' grooves at end
of cylinder head -
Inlet manifold
gasketSTC 50550
Manual
Gearbox -
R380Gear selector
housingSTC 4404
Manual
Gearbox -
R380Selector housing
boltsSTC 50552
Manual
Gearbox -
R380Input shaft oil seal
housingSTC 4404
Manual
Gearbox -
R380Reverse inhibitor
shaft threadsSTC 50552

CAPACITIES, FLUIDS, LUBRICANTS AND SEALANTS
09-5
Manual
Gearbox -
R380Gate plate bolts STC 50552
Manual
Gearbox -
R380Gear case to
extension housingSTC 4404
Manual
Gearbox -
R380Extension housing
boltsSTC 50552
Manual
Gearbox -
R380Gear change lever
yoke Allen screwSTC 50552
Manual
Gearbox -
R380Gear case to centre
plateSTC 4404
Manual
Gearbox -
R380Detent plugs STC 50552
Manual
Gearbox -
R380Bias spring
adjustment plate
boltsSTC 50552
Transfer Box -
LT230SEBottom cover plate STC 4600
Transfer Box -
LT230SEBottom cover plate
boltsSTC 50552
Transfer Box -
LT230SEFront output
housing core plugSTC 3811
Transfer Box -
LT230SETransfer box to
gear case bolts -
Petrol and Diesel
enginesSTC 50552
Transfer Box -
LT230SETransfer box to
gear case studs -
Petrol and Diesel
enginesSTC 50552
Transfer Box -
LT230SERear cover STC 4600
Transfer Box -
LT230SEDifferential warning
lamp switch(es)STC 50552
Transfer Box -
LT230SEHigh/Low selector
warning lamp
switchSTC 50552
Transfer Box -
LT230SERear output shaft
housingSTC 4600
Transfer Box -
LT230SERear output shaft
housing boltsSTC 50552
Transfer Box -
LT230SEHigh/Low selector
fork set screwSTC 50552
Transfer Box -
LT230SEInterlock solenoid
selector cover - Up
to 03 MYSTC 4600
Transfer Box -
LT230SEInterlock solenoid
circlip - 03 MY
onwardsSTC 50551
Transfer Box -
LT230SENeutral sensor STC 50552
Transfer Box -
LT230SEIntermediate shaft
retaining plate boltSTC 50552Transfer Box -
LT230SESide cover STC 4600
Transfer Box -
LT230SESide cover bolts STC 50552
Transfer Box -
LT230SEDifferential lock
selector shaft
detent plugSTC 50552
Transfer Box -
LT230SEDifferential lock
selector housing
boltsSTC 50552
Transfer Box -
LT230SEFront output shaft
housingSTC 4600
Transfer Box -
LT230SEFront output shaft
housing boltsSTC 50552
Transfer Box -
LT230SEHigh/Low selector
shaft detent plugSTC 50552
Transfer Box -
LT230SEInput gear bearing
housingSTC 4600
Transfer Box -
LT230SERear cover stud nut
and boltSTC 50552
Transfer Box -
LT230SEHigh/Low cross
shaft housingSTC 4600
Transfer Box -
LT230SEHigh/Low cross
shaft housing boltsSTC 50552
Automatic
gearbox -
ZFHP22-24Torque converter
housing to engine
boltsSTC 50553
Rear Axle and
Final DriveDifferential cover to
casingSTC 3811
Rear Axle and
Final DriveDifferential cover to
casing boltsSTC 50552
Front axle Differential cover to
casingSTC 3811
Front axle Differential cover to
casing boltsSTC 50552
Front
suspensionDrive shaft to hub STC 50554
Rear
suspensionDrive shaft to hub STC 50554
Rear
suspensionSLS air compressor
boltsSTC 50552

MAINTENANCE
PROCEDURES 10-17
Manual gearbox
WARNING: Avoid excessive skin contact with
mineral oil. Mineral oils remove the natural fats
from the skin, leading to dryness, irritation and
dermatitis.
Check/top-up oil level
1.Release fixings, remove rear underbelly panel.
2.Clean area around oil filler/level plug.
3.Remove oil filler/level plug.
4.Check that oil level is to bottom of oil filler/level
plug hole.
5.Top-up level (if required) with recommended oil
to bottom of filler/level plug hole.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
6.Remove all traces of sealant from threads of oil
filler/level plug.
7.Apply Loctite 290 to threads of oil filler/level
plug.
8. Fit manual gearbox filler/level plug and tighten
to 30 Nm (22 lbf.ft).
9.Remove all traces of oil from gearcase.
10.Fit rear underbelly panel, secure fixings.Replace oil
1.Release fixings, remove rear underbelly panel.
2.Place a suitable container beneath gearbox
drain plug.
3.Clean area around oil filler/level and drain
plugs.
4.Remove oil filler/level plug.
5.Remove oil drain plug, remove and discard
sealing washer.
6.Allow oil to drain.
7.Clean magnet in oil drain plug.
8.Fit new sealing washer to oil drain plug.
9.Fit manual gearbox drain plug and tighten to 50
Nm (37 lbf.ft).
10.Fill gearbox with recommended oil to bottom of
filler/level plug hole.
+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
11.Remove all traces of sealant from threads of oil
filler/level plug.
12.Apply Loctite 290 to threads of oil filler/level
plug.
13. Fit manual gearbox filler/level plug and tighten
to 30 Nm (22 lbf.ft).
14.Remove all traces of oil from gearcase.
15.Fit rear underbelly panel, secure fixings.

MAINTENANCE
10-18 PROCEDURES
Automatic gearbox
WARNING: Avoid excessive skin contact with
mineral oil. Mineral oils remove the natural fats
from the skin, leading to dryness, irritation and
dermatitis.
Replace oil filter
1.Replace oil filter.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Filter - oil.
Replace oil
1. Ensure that gearbox is cool. Apply
handbrake and securely chock front and rear
wheels.
2.Place a suitable container beneath gearbox.
3.Clean area around oil filler/level and drain
plugs.
4.Remove oil drain plug, remove and discard
sealing washer.
5.Allow oil to drain.
6.Fit new sealing washer to oil drain plug.
7.Fit automatic gearbox drain plug and tighten to
15 Nm (11 lbf.ft).
8.Remove oil filler/level plug, remove and discard
sealing washer.
9.Fill gearbox with recommended oil to bottom of
oil level/filler plug hole.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
10.Select 'P' (Park).
11.Ensure handbrake is applied.
12.Start engine and allow it to idle.
13.Apply footbrake. 14.Move selector lever through all gear positions,
while continuing to fill the gearbox. Select 'P'
(Park).
15.With engine idling, continue filling gearbox until
a 2 mm bead of oil runs from oil filler/level plug
hole.
16.Fit new sealing washer to automatic gearbox
filler/level plug, fit plug and tighten to 30 Nm (22
l b f . f t ) .
17.Stop engine.
18.Remove all traces of oil from gearbox casing.

MAINTENANCE
PROCEDURES 10-25
Engine, gearbox, transfer box and axles
Check
1.Check for oil leaks from engine, gearbox
(manual and automatic), transfer box and front
and rear axles; pay particular attention to areas
around oil seals.
Exhaust system
Check
1.Check for signs of exhaust system leaks,
damage and security.
Steering box and front suspension
Check/tighten steering box fixings
1.Check steering box fixings and tighten to 90
Nm (66 lbf.ft).
Check/tighten front axle suspension fixings
1.Check/tighten front suspension LH radius arm
fixings.

+ TORQUE WRENCH SETTINGS,
Front suspension.

MAINTENANCE
PROCEDURES 10-31
Road/roller test
WARNING: Roller test must be restricted to 3
mph (5 km/h). If 2 wheel rolling road is to be used,
disconnect propeller shaft from the transfer box
output shaft driving the axle which is NOT on the
rolling road.
Testing
1. 2 wheel rolling road: Engage differential lock
using a 10 mm open ended spanner on flats
machined on differential lock selector
shaft.Switch on ignition and check that the
differential lock, electronic brake
distribution and hill descent warning lamps
are illuminated.
2.Check for correct operation of starter switch,
ensure engine starts correctly; leave the engine
running.
3.Check for correct operation of starter switch,
ensure engine starts correctly; leave the engine
running.
4.With vehicle stationary, turn steering from lock
to lock. Check for smooth operation and ensure
there is no undue noise from power steering
pump or drive belt.
5.Depress clutch and select all gears in turn,
check for smooth, notch free engagement.6. Check all vehicle systems for correct
operation.
7.Check for unusual engine, gearbox and
suspension noises.
8.Check braking system operation.
9.Check for smooth gear engagement.
10.Check engine performance.
11.Check operation of all instruments and warning
devices where practicable.
12.Where possible, check for correct operation of
hill descent control (HDC) mechanism. This
should not be carried out if excessive journey
time is required.
13.After road/roller test, carry out a final inspection
of vehicle, with vehicle on a ramp.
14.Check all fluid levels and top-up if necessary.
15. 2 wheel rolling road: Ensure differential lock is
disengaged and propeller shaft is connected on
completion of test. Switch on ignition and
check that differential lock, electronic brake
distribution and hill descent warning lamps
are extinguished.