torque LAND ROVER DISCOVERY 1999 Repair Manual
[x] Cancel search | Manufacturer: LAND ROVER, Model Year: 1999, Model line: DISCOVERY, Model: LAND ROVER DISCOVERY 1999Pages: 1529, PDF Size: 34.8 MB
Page 617 of 1529
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
Page 618 of 1529
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.
Page 624 of 1529
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.
Page 628 of 1529
AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-31
40.Fit suitable strap to retain torque converter.
Refit
1.Clean gearbox to engine mating faces.
2.Remove torque converter retaining strap.
3.With assistance position gearbox to engine.
4.Fit but do not tighten six bolts securing gearbox
housing to engine.
5.Connect multiplug to gearbox and tighten
locking ring.
6.Connect multiplug to inhibitor switch.
7. If fitted: Connect and adjust differential lock
selector cable.
+ TRANSFER BOX - LT230SE,
ADJUSTMENTS, Cable - selector -
differential lock - adjust.
8.Position selector lever to inhibitor switch and
tighten nut to 25 Nm (18 lbf.ft).
9.Position selector cable to gearbox and secure
with 'C' clip.
10.Clean oil pipe unions and fit new 'O' rings.
11.Position and tighten pipe unions to gearbox.
12.Position and tighten oil cooler pipe clamps.
13.Position and tighten oil cooler pipe clips to
engine sump and alternator bracket.
14.Position engine RH and LH rear mountings
and tighten bolts to 85 Nm (63 lbf.ft) and nuts to
85 Nm (63 lbf.ft).
15.Secure gearbox breather pipes to bulkhead
clip.
16. Up to 03 Model Year - If fitted: Connect 2
Lucars to differential lock warning lamp switch
and multiplugs to high/low ratio switch and
neutral sensor.
17. 03 Model Year onwards - If fitted: Connect
differential lock warning lamp switch multiplugs
to main harness.
18.Position cable tie and multiplug to transfer box
bracket.
19.Connect high/low ratio selector cable to
selector lever and secure with clevis pin. 20.Position high/low ratio selector cable to
abutment bracket and secure with 'C' clip.
21. Models fitted with high/low shift interlock
solenoid: Position interlock solenoid harness
to high/low shift cable, fit sleeve around cable
and harness.
22. Models fitted with high/low shift interlock
solenoid: Connect solenoid multiplug to main
harness and secure multiplug to bracket.
23.Position handbrake backplate and tighten bolts
to 75 Nm (55 lbf.ft).
24.Fit hand brake drum and tighten screw.
25.Remove bolts securing tool LRT-99-008A to
gearbox.
26.Rotate engine to align torque converter, fit new
bolts and tighten to 50 Nm (37 lbf.ft).
27.Fit rear propeller shaft.
+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.
28.Fit front propeller shaft.
+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
29.Fill transfer gearbox with oil.
+ MAINTENANCE, PROCEDURES,
Transfer box.
30.Fill automatic gearbox with oil.
+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
31.Position intermediate silencer and secure to
mounting rubbers.
32.Clean silencer and tail pipe mating faces.
33.Position new gasket to tail pipe and tighten
nuts to 25 Nm (18 lbf.ft).
34.Fit exhaust front pipe.
+ MANIFOLDS AND EXHAUST
SYSTEMS - Td5, REPAIRS, Pipe - front.
35.Fit bolt securing closing plate to gearbox
housing and tighten to 7 Nm (5.2 lbf.ft).
36.Fit upper bolts securing gearbox housing to
engine and tighten to 50 Nm (37 lbf.ft).
37.Fit starter motor.
+ CHARGING AND STARTING,
REPAIRS, Starter motor - diesel.
38.Tighten remaining gearbox housing to engine
bolts to 50 Nm (37 lbf.ft).
39.Connect battery earth lead.
40.Fit battery cover and secure with fixings.
41.Check and adjust selector cable.
+ AUTOMATIC GEARBOX - ZF4HP22
- 24, ADJUSTMENTS, Cable - selector.
Page 629 of 1529
AUTOMATIC GEARBOX - ZF4HP22 - 24
44-32 REPAIRS
Gearbox - convertor and transfer
gearbox - V8
$% 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 8 bolts securing centre cross member
and remove cross member.
5.Remove exhaust front pipe.
+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Front pipe.
6.Remove 3 nuts securing intermediate silencer
to tail pipe.
7.Release and remove silencer from rubber
mountings.
8.Drain automatic gearbox oil.
+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
9.Drain transfer gearbox oil.
+ MAINTENANCE, PROCEDURES,
Transfer box.
10.Remove front propeller shaft
+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.11.Remove rear propeller shaft
+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.
12.Remove plug from torque converter housing to
access torque converter bolts.
13.Remove and discard 4 bolts securing torque
converter to drive plate.
14.Remove hand brake drum retaining screw and
remove brake drum.
15.Remove 4 bolts from hand brake back plate,
release back plate and tie aside.
Page 632 of 1529
AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-35
32.Remove 'C' clip securing selector cable to
gearbox bracket.
33.Remove nut securing selector lever to inhibitor
switch and release lever.
34.Disconnect multiplug from inhibitor switch.
35.Loosen gearbox multiplug locking ring and
disconnect plug.
36.Lower gearbox sufficiently to access bell
housing bolts, take care not to trap any pipes or
cables when lowering gearbox.
37.Remove 14 bolts securing gearbox to engine.
38.With assistance remove gearbox from engine.39.Fit suitable strap to retain torque converter.
Refit
1.Clean gearbox to engine mating faces.
2.Remove torque converter retaining strap.
3.With assistance position gearbox to engine.
4.Fit gearbox bell housing bolts and tighten to 46
Nm (34 lbf.ft)..
5.Connect multiplug to gearbox and tighten
locking ring.
6.Connect inhibitor switch multiplug.
7. If fitted: Connect and adjust differential lock
selector cable.
+ TRANSFER BOX - LT230SE,
ADJUSTMENTS, Cable - selector -
differential lock - adjust.
8.Position selector lever to inhibitor switch and
tighten nut to 25 Nm (18 lbf.ft).
9.Position selector cable to gearbox and secure
with 'C' clip.
10.Clean oil pipe unions and fit new 'O' rings.
11.Position and tighten pipe unions to gearbox.
12.Position and tighten oil cooler pipe clamps.
13.Position and tighten oil cooler pipe clip to
engine sump.
14.Position engine RH and LH rear mountings
and tighten bolts to 85 Nm (63 lbf.ft) and nuts to
85 Nm (63 lbf.ft).
15.Secure gearbox breather pipes to bulkhead
clip.
16. Up to 03 Model Year - If fitted: Connect 2
Lucars to differential lock warning lamp switch
and multiplugs to high/low ratio switch and
neutral sensor.
17. 03 Model Year onwards - If fitted: Connect
differential lock warning lamp switch multiplugs
to main harness.
18.Position cable tie and multiplug to transfer
gearbox bracket.
19.Connect high/low ratio selector cable to
selector lever and secure with clevis pin.
20.Position high/low ratio selector cable to
abutment bracket and secure with 'C' clip.
Page 633 of 1529
AUTOMATIC GEARBOX - ZF4HP22 - 24
44-36 REPAIRS
21. Models fitted with high/low shift interlock
solenoid: Position interlock solenoid harness
to high/low shift cable, fit sleeve around cable
and harness, secure sleeve.
22. Models fitted with high/low shift interlock
solenoid: Connect solenoid multiplug to main
harness and secure multiplug to bracket.
23.Position hand brake back plate and tighten
bolts to 75 Nm (55 lbf.ft).
24.Fit hand brake drum and tighten screw.
25.Remove bolts securing tool LRT-99-008A to
gearbox.
26.Rotate engine to align torque converter, fit new
bolts and tighten to 50 Nm (37 lbf.ft).
27.Fit access plug to torque converter housing.
28.Fit rear propeller shaft.
+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.
29.Fit front propeller shaft.
+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
30.Fill transfer gearbox with oil.
+ MAINTENANCE, PROCEDURES,
Transfer box.
31.Fill automatic gearbox with oil.
+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
32.Position intermediate silencer and secure to
mounting rubbers.
33.Clean silencer and tail pipe mating faces.
34.Position new gasket to tail pipe and tighten nuts
to 40 Nm (30 lbf.ft).
35.Fit exhaust front pipe.
+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Front pipe.
36.Position centre cross member, fit bolts and
tighten to 26 Nm (19 lbf.ft).
37.Connect battery earth lead.
38.Fit battery cover and secure fixings.
39.Check and adjust selector cable.
+ AUTOMATIC GEARBOX - ZF4HP22
- 24, ADJUSTMENTS, Cable - selector.
Page 634 of 1529
AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-37
Torque converter and oil seal
$% 44.17.07
Remove
1.Remove automatic gearbox.
l
+ AUTOMATIC GEARBOX -
ZF4HP22 - 24, REPAIRS, Gearbox -
convertor and transfer gearbox - Diesel.
l
+ AUTOMATIC GEARBOX -
ZF4HP22 - 24, REPAIRS, Gearbox -
convertor and transfer gearbox - V8.
2.Remove retaining strap from torque convertor.
3.Fit tool LRT-44-010 to torque converter and
remove torque converter from gearbox.
4.Remove tool LRT-44-010 from converter.
5.Remove oil seal from converter housing. Refit
1.Clean oil seal running surfaces.
2.Lubricate oil seal with transmission fluid.
3.Fit new seal into converter housing using tool
LRT-44-001.
4.Fit tool LRT-44-010 to torque converter.
5.Align oil pump drive and fit torque converter to
gearbox.
6.Remove tool LRT-44-010 from torque
converter.
7.Fit torque converter retaining strap.
8.Fit automatic gearbox.
l
+ AUTOMATIC GEARBOX -
ZF4HP22 - 24, REPAIRS, Gearbox -
convertor and transfer gearbox - Diesel.
l
+ AUTOMATIC GEARBOX -
ZF4HP22 - 24, REPAIRS, Gearbox -
convertor and transfer gearbox - V8.
Page 635 of 1529
AUTOMATIC GEARBOX - ZF4HP22 - 24
44-38 REPAIRS
Housing - torque converter
$% 44.17.01
Remove
1.Remove torque converter oil seal.
+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Torque converter and oil
seal.
2.Remove 18 bolts and plain washers securing
torque converter and intermediate plate to
gearbox casing. Note the position of the 4 bolts
that have sealant applied to the bolt threads
and 6 bolts, (outer ring), which are shorter.
3.Hold input shaft in position and carefully
remove the converter housing and intermediate
plate from gearbox casing.
4.Note the position of the Torrington race on the
forward clutch hub and the thrust washer which
will stay attached to the intermediate plate by
fluid adhesion.
5.Remove and discard intermediate plate gasket.
6.Remove thrust washer from intermediate plate.
7.Separate converter housing from intermediate
plate.Refit
1.Clean converter housing, intermediate plate
and gearbox casing mating faces.
2.Clean bolts and plain washers and sealant from
4 bolt threads.
3.Apply Petroleum Jelly to new gasket and
position on gearbox casing.
4.Apply Petroleum Jelly to thrust washer and
Torrington race.
5.Correctly position Torrington race and thrust
washer to forward clutch hub.
6.Position intermediate plate and converter
housing to gearbox casing.
7.Apply sealant, Part No. STC 50553 to 4 longer
bolt threads and fit bolts in the positions shown.
8.Fit remaining bolts and tighten progressively in
a diagonal sequence to 46 Nm (34 lbf.ft).
9.Place LRT-44-003/1 into pump housing, tighten
screws to secure LRT-44-003/1 to input shaft.
10.Clamp a suitable steel base to converter
housing flange.
11.Mount DTI gauge and position gauge probe
onto LRT-44-003/1 and zero gauge.
M44 1343
M44 1345
M44 1343
M44 1358
LRT-44-003/1
Page 636 of 1529
AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-39
12.Check that the axial end-float is between 0.2 to
0.4 mm. If end-float is not within limits, replace
existing thrust washer, positioned at rear of
intermediate plate, with a suitable thickness
thrust washer to give the required end-float.
13.Remove DTI gauge and base plate.
14.Fit torque converter oil seal.
+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Torque converter and oil
seal.
Gasket - intermediate plate
$% 44.20.11
Remove
1.Remove torque converter oil seal.
+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Torque converter and oil
seal.
2.Remove 12 bolts and plain washers securing
converter housing and intermediate plate to
gearbox casing. Note the position of the 4 bolts
that have sealant applied to the bolt threads.
3.Hold input shaft in position and carefully lift off
converter housing and intermediate plate as an
assembly. Note the position of the Torrington
race on the forward clutch hub, and the thrust
washer which will stay attached to the
intermediate plate by fluid adhesion.
4.Remove and discard intermediate plate gasket.
5.Remove thrust washer from intermediate plate.
M44 1344
M44 1345