LAND ROVER DISCOVERY 1999 Workshop Manual

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-44 REPAIRS
Seal - rear extension housing
$% 44.20.18
Remove
1.Remove transfer box

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - Diesel.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - V8.
2.Drain automatic gearbox oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
3.Remove rear extension housing oil seal from
gearbox. Refit
1.Clean oil seal recess in gearbox and running
surface on input shaft.
2.Lubricate oil seal running surface with
transmission oil.
3.Using tool LRT-44-001 fit oil seal to extension
housing.
4.Fit transfer box

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - Diesel.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - V8.
5.Fill automatic gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-45
Gasket - rear extension housing.
$% 44.20.19
Remove
1.Drain automatic gearbox oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
2.Remove transfer gearbox.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - Diesel.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - V8.
3.Remove 9 bolts securing rear extension
housing to gearbox case and remove housing.
4.Remove and discard gasket. Reassembly
1.Clean rear extension and mating face.
2.Position new gasket to gearbox case.
3.Position rear extension housing and tighten
bolts to 25 Nm (18 lbf.ft).
4.Fit transfer gearbox.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - Diesel.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - V8.
5.Fill automatic gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-46 REPAIRS
Parking pawl assembly.
$% 44.28.07
Remove
1.Drain automatic gearbox oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
2.Remove transfer gearbox.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - Diesel.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - V8.
3.Remove and discard 9 bolts securing extension
housing to gearbox case.
4.Remove extension housing and discard gasket. 5.Remove Torx screw and discard, lift off parking
pawl guide and guide plate.
6.Remove ratchet, spring and pivot pin.
7. Td5 models: Remove spacer from output
shaft.
8.Remove park lock gear.
9.Remove and discard 'O' ring from output shaft.
M44 1109B
97
8

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-47
Refit
1.Clean park lock components.
2.Lubricate and fit new 'O' ring to output shaft.
3.Position park lock gear on the output shaft.
4. Td5 models: Fit the spacer.
CAUTION: Ensure that spacer is fitted on
output shaft - Tdi Models only. If spacer is
omitted, park gear and speed sensor may
move out of position.
5.Position pivot pin, spring and ratchet.
6.Position parking pawl guide and guide plate,
tighten Torx screw to 10 Nm (8 lbf.ft).
7.Clean extension housing and gearbox case.
8.Position new gasket to gearbox case.
9.Position extension housing and tighten bolts to
25 Nm (18 lbf.ft).
10.Fit transfer gearbox.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - Diesel.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - V8.
11.Fill automatic gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
Gasket - oil sump
$% 44.24.05
Remove
1.Raise vehicle on ramp.
2.Drain automatic gearbox oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
3.Remove 6 bolts and spacers securing oil sump
to gearbox, remove sump and discard gasket.
Refit
1.Clean oil sump and mating face.
2.Fit new gasket to oil sump, position sump to
gearbox.
3.Position spacers and tighten bolts to 8 Nm (6
lbf. ft).
4.Fill automatic gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
5.Lower vehicle.

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-48 REPAIRS
Filter - oil
$% 44.24.07
Remove
1.Remove oil sump gasket.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Gasket - oil sump.
2.Remove Torx screw securing oil pick-up tube
and remove tube.
3.Remove 2 Torx screws securing filter to valve
body and discard 'O' rings. Refit
1.Clean filter and pick-up tube using a lint free
cloth.
2.Fit new 'O' rings to filter.
3.Position filter and tighten Torx screws to 8 Nm
(6 lbf.ft).
4.Position oil pick-up tube and tighten Torx
screw to 8 Nm (6 lbf.ft).
5.Fit oil sump gasket.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Gasket - oil sump.

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-49
Cooler - fluid - Td5
$% 44.24.10
Remove
1.Remove intercooler.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Intercooler.
2.Disconnect fluid temperature sensor multiplug.
3.Position absorbent cloth under each gearbox
cooler hose connection to collect spillage.
4.Push against coupling release ring and
disconnect both fluid hoses from cooler.
5.Remove screw and release cooler from
radiator.
6.Carefully remove cooler.7.Remove temperature sensor and discard
sealing washer.
Refit
1.Use new sealing washer and tighten
temperature sensor to 14 Nm (10 lbf.ft).
2.Fit cooler, engage with radiator and secure with
screw.
3.Connect temperature sensor multiplug.
4.Ensure connections are clean and fit hoses to
cooler.
5.Fit intercooler.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Intercooler.
6.Check and if necessary top up gearbox fluid.

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-50 REPAIRS
Cooler - fluid - V8
$% 44.24.10
Remove
1. If fitted: Remove engine oil cooler.

+ ENGINE - V8, REPAIRS, Cooler -
engine oil.
2.Disconnect fluid temperature sensor multiplug.
3.Position absorbent cloth under each gearbox
cooler hose connection to collect spillage.
4.Push against coupling release ring and
disconnect both fluid hoses from cooler.
CAUTION: Always fit plugs to open
connections to prevent contamination.
5.Remove screw and release cooler from
radiator.
6.Carefully move radiator towards engine and
remove cooler.7.Remove temperature sensor and discard
sealing washer.
Refit
1.Use new sealing washer and tighten
temperature sensor to 14 Nm (10 lbf.ft).
2.Fit cooler, engage with radiator and secure with
screw.
3.Connect temperature sensor multiplug.
4.Ensure connections are clean and fit hoses to
cooler.
5. If fitted:Fit engine oil cooler.

+ ENGINE - V8, REPAIRS, Cooler -
engine oil.
6.Check and if necessary top up gearbox fluid.

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-51
Valve body assembly
$% 44.40.01
Remove
1.Remove gearbox oil filter.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Filter - oil.
2.Remove 2 bolts securing speed sensor
harness bracket to valve body.
3.Disconnect multiplug from gearbox housing.
4.Using a 30 mm socket, remove nut securing
multiplug connector block to gearbox housing. 5.Remove 6 long bolts securing valve body to
gearbox.
6.Remove 5 short bolts securing valve body to
gearbox.

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-52 REPAIRS
7.Release speed sensor and remove valve body.
8.Remove and discard 'O' ring from multiplug
connector. Refit
1.Clean valve body and mating faces.
2.Fit new 'O' ring to multiplug connector block.
3.With assistance, position multiplug to gearbox
housing and tighten nut.
4.Align valve body to gearbox, ensure manual
valve is correctly located. Position speed
sensor retaining bracket, and tighten screws
to 8 Nm (6 lbf.ft).
5.Connect multiplug to gearbox connector.
6.Fit gearbox oil filter.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Filter - oil.

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-53
Seal - valve body
$% 44.20.13
Remove
1.Remove valve body assembly.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Valve body assembly.
2.Remove circlips and springs from gearbox
casing noting location of long and short
springs.
3.Using tool LRT-44-005, remove and discard
seals from gearbox casing. Refit
1.Clean gearbox casing, springs and circlips.
2.Fit new seals using tool LRT-44-005, ensure
seals are fully seated.
3.Position springs in their correct locations and
secure with circlips.
4.Fit valve body assembly.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Valve body assembly.