clutch LAND ROVER DISCOVERY 1999 Manual PDF

TRANSFER BOX - LT230SE
OVERHAUL 41-65
9. 03 Model Year onwards:Note position of
longest bolt and remove 8 bolts securing front
output shaft housing to main casing; remove
housing.
10. 03 Model Year onwards:Remove 3 bolts
securing differential lock selector housing and
bracket, remove housing.
11. 03 Model Year onwards:Remove and discard
'O' rings from selector housing.
12. 03 Model Year onwards:Remove differential
lock detent plug, recover spring and ball.
13.Compress differential lock selector fork spring
and remove retaining clips from each end of
spring.
14.Withdraw differential lock selector shaft from
front output housing, recover spring and
remove selector fork.
15.Position tool LRT-51-003 to output shaft drive
flange, remove and discard nut. 16.Remove and discard steel and felt washers.
Remove output shaft drive flange.
17.Using a copper mallet, drive output shaft from
housing.
18.Noting its fitted position, remove bearing
spacer from output shaft.
19.Noting its fitted position, remove dog clutch
from output shaft.
20.Remove and discard oil seal from housing.
Reassembly
1.Clean differential lock components. Remove all
traces of sealant from mating faces of
housings, side cover, bolt threads, detent plugs
and differential lock warning lamp switches.
2.Lubricate components with gearbox oil.
3.Using tool LRT-41-012, fit new output shaft oil
seal.
CAUTION: Oil seal must be fitted dry.

TRANSFER BOX - LT230SE
41-66 OVERHAUL
4.Fit bearing spacer to output shaft with chamfer
on spacer towards threaded end.
5.Fit dog clutch with flange on clutch facing
towards splined end.
6.Using a copper mallet, drive output shaft into
bearing.
7.Compress differential lock selector spring and
fit selector fork.
8.Position selector fork to groove in dog clutch.
9.Fit differential lock selector shaft and locate in
housing recess, rotate shaft until the two flats
for retaining clips are at right angles to the
cover plate mating face.
10.Compress differential lock selector spring and
fit retaining clips at each end of spring.
CAUTION: Ensure ends of spring are fully
seated in recess in clips.
11.Apply sealant, Part No. STC 4600 to front
output shaft housing.
12.Position housing ensuring that output shaft and
dog clutch splines are correctly engaged.
13.Apply sealant, Part No. STC 50552 to threads
of bolts.
14.Fit front output shaft housing bolts and tighten
in a diagonal sequence to 45 Nm (33 lbf.ft).
15.Apply sealant, Part No. STC 4600 to mating
face of high/low selector housing.
16.Position high/low selector housing to front
output housing ensuring that high/low selector
finger is located in groove in selector shaft.
17. Position multiplug and selector cable brackets
to high/low selector housing
18.Apply sealant, Part No. STC 50552 to threads
of high/low selector housing bolts.
19.Fit bolts and tighten to 25 Nm (18 lbf.ft).20.Fit differential lock detent ball and spring.
21. Up to 03 Model Year: Apply sealant, Part No.
STC 50552 to threads of detent plug.
22. Up to 03 Model Year: Fit and tighten detent
plug, then unscrew 2 complete turns.
23. 03 Model Year onwards: Apply sealant, Part
No. STC 50552 to threads of differential lock
detent plug.
24.Fit differential lock detent ball and spring.
25.Fit detent plug and tighten until head of plug is
level with face of housing.
26.Using a suitable straight edge, check that head
of plug is correctly positioned, screw plug in or
out as necessary.
27.Lubricate and fit new 'O' rings to differential lock
selector housing.
28.Fit selector housing, ensure selector finger is
located in shaft recess.
29.Position bracket to selector housing.
30.Apply sealant, Part No. STC 50552 to threads
of selector housing bolts, fit bolts and tighten to
25 Nm (18 lbf.ft).
M41 7886

TRANSFER BOX - LT230SE
41-70 OVERHAUL
7.Position dial gauge with stylus contacting input
gear, push input gear rearwards and zero
gauge.
8.Push input gear forwards and note gauge
reading.
9.Calculate thickness of shim required using the
formula - A+B+C=D where:
lA= Thickness of installed shim - 3.15 mm
(0.12 in)
lB= Recorded end-float.
lC= Required pre-load - 0.05 mm (0.002 in).
lD= Thickness of shim required.
10.If an alternative shim is required to establish
correct pre-load, fit an alternative shim. Shims
are available from 3.15 to 4.00 mm (0.12 to
0.16 in) thickness, in increments of 0.05 mm
(0.002 in).
11.Remove 2 bolts, remove bearing housing and
input gear.
12.Lubricate input gear and bearings with
recommended oil.
13.Position input gear into main casing.
14.Apply sealant, Part No. STC 4600to bearing
housing and cover.
15.Apply sealant, Part No. STC 50552 to threads
of cover bolts and stud nut.
16.Position bearing housing/cover, align reference
marks and tighten bolts and stud nut by
diagonal selection to 45 Nm (33 lbf.ft).
17.Using tool LRT-37-014 fit new input shaft oil
seal.
CAUTION: Oil seal must be fitted dry.
Low gear - differential
$% 41.20.62
Disassembly
1.Remove differential.

+ TRANSFER BOX - LT230SE,
OVERHAUL, Dog clutch - differential lock.
2.Secure differential in a soft jawed vice.
3.Release staking from bearing retaining nut.
4.Using tool LRT-41-007 remove and discard
bearing retaining nut.
5.Position tool LRT-99-002. to a vice.
6.Position tool LRT-41-001 around rear
differential bearing, position differential to tool
LRT-99-002 and press off bearing.

AUTOMATIC GEARBOX - ZF4HP22 - 24
DESCRIPTION AND OPERATION 44-7
The gearbox consists of a torque converter housing, an intermediate plate, a gearbox housing and a rear extension
housing, bolted together in series. The rear of the gearbox is supported by a rubber mounting installed between a
mounting bracket on the gearbox and the LH chassis rail. A heat shield is installed on the mounting to protect it from
the exhaust.
Sectioned view of gearbox
1Lock-up clutch
2Impeller
3Turbine
4Forward drive clutch
5Reverse drive clutch
6Brake clutch
7Brake clutch
8Brake clutch
9Epicyclic gear set10Epicyclic gear set
11Clutch
12Brake clutch
13Output shaft
14Freewheel (one way clutch)
15Freewheel (one way clutch)
16Freewheel (one way clutch)
17Stator and one way clutch
Torque converter housing
The torque converter housing attaches the gearbox to the engine and contains the torque converter. Different torque
converter housings are used to accommodate the difference between the V8 and Td5 engine interfaces. The torque
converter is connected to the engine drive plate and transmits the drive from the engine to the gearbox input shaft.
When engaged, a hydraulic lock-up clutch in the torque converter prevents slippage, to give a direct drive from the
engine to the gearbox for improved driving response.
Intermediate plate
The intermediate plate supports the gearbox input shaft and provides the interface between the transmission fluid
pump and the lubrication circuit. The pump attaches to the front of the intermediate plate and is driven by the impeller
in the torque converter. The pump pressurises transmission fluid drawn from the sump on the gearbox housing. The
pressurised fluid then circulates through the torque converter and gearbox housing components for cooling,
lubrication and gear shift purposes. Ports around the outer periphery of the intermediate plate provide the inlet and
outlet connections to the fluid cooler and a pressure take-off point for servicing.

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-8 DESCRIPTION AND OPERATION
Gearbox housing
The gearbox housing contains two epicyclic gear sets on input and output shafts. Hydraulic brake clutches on the
shafts, control which elements of the gear sets are engaged, and their direction of rotation, to produce the P and N
selections, four forward gear ratios and one reverse gear ratio.
Gear ratios
Gear Ratio
1st 2.480 : 1
2nd 1.480 : 1
3rd 1.000 : 1
4th 0.728 : 1
Reverse 2.086 : 1

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-10 DESCRIPTION AND OPERATION
The lock-up and brake clutches are operated by pressurised transmission fluid from the valve block in the sump. A
manual valve and four solenoid valves, also known as Motorised Valves (MV), control the supply of pressurised
transmission fluid from the valve block:
lThe manual valve controls the supply in P, R, N and D.
lSolenoid valves MV 1 and MV 2 control the supplies that operate the brake clutches for shift control.
lSolenoid valve MV 3 controls the supply that operates the lock-up clutch.
lSolenoid valve MV 4 modulates the pressure of the supplies to the brake clutches, to control shift quality.
Operation of the manual valve is controlled by the selector lever assembly. In the gearbox, a selector shaft engages
with the manual valve. The selector shaft is connected to the selector lever assembly via the selector cable and a
selector lever on the left side of the gearbox. The selector shaft also operates a mechanism that locks the output shaft
when P is selected.
Operation of the solenoid valves is controlled by the EAT ECU.
An output shaft speed sensor in the gearbox housing outputs a signal to the EAT ECU. The EAT ECU compares
output shaft speed with engine speed to determine the engaged gear, and output shaft speed with vehicle speed to
confirm the range selected on the transfer box.
A bayonet lock electrical connector in the gearbox casing, to the rear of the selector lever, connects the solenoid
valves and the output shaft speed sensor to the vehicle wiring.
A pressed steel sump encloses the valve block and collects transmission fluid draining from the gearbox housing. A
suction pipe and filter on the underside of the valve block connect to the inlet side of the fluid pump. A magnet is
installed in the sump to collect any magnetic particles that may be present. A level plug and a drain plug are installed
in the sump for servicing.
Rear extension housing
The rear extension housing provides the interface between the gearbox housing and the transfer box. A splined
extension shaft, secured to the gearbox output shaft by a bolt, transmits the drive from the gearbox to the transfer
box. A seal in the rear of the housing prevents leakage past the extension shaft. A breather pipe, attached to the left
side of the rear extension housing, ventilates the interior of the gearbox and rear extension housings to atmosphere.
The open end of the breather pipe is located in the engine compartment at the right front corner of the engine sump
on gearboxes fitted to early vehicles and is clipped to the top of the gearbox on later vehicles.
Gearbox power flows
The following Figures show the power flow through the gearbox for each forward gear when D is selected, and for
reverse. The key to the Item numbers on the Figures, and in parenthesis in the accompanying text, can be found on
the 'Sectioned view of gearbox' Figure, above.
1st Gear (D selected)
Clutches (4) and (11) are engaged. The front planet gear carrier of gear set (9) locks against the gearbox housing
through freewheel (15) when the engine powers the vehicle, and freewheels when the vehicle is coasting. Gear set
(10) rotates as a solid unit with the front planet gear carrier. In 1st gear hold brake clutch (8) is applied to provide
overrun braking.

AUTOMATIC GEARBOX - ZF4HP22 - 24
DESCRIPTION AND OPERATION 44-11
2nd Gear (D selected)
Clutches (4), (6), (7) and (11) are engaged. Freewheel (15) overruns. The hollow shaft with the sun wheel of gear set
(9) is locked. Gear set (10) also rotates as a solid unit.
3rd Gear (D selected)
Clutches (4), (5), (7) and (11) are engaged. Freewheels (15) and (16) are overrun. Gear sets (9) and (10) rotate as a
solid unit.
4th Gear (D selected)
Clutches (4), (5), (7) and (12) are engaged. Freewheels (14), (15) and (16) are overrun. Gear set (9) rotates as a solid
unit. The hollow shaft with the sun wheel of gear set (10) is locked.

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-12 DESCRIPTION AND OPERATION
Reverse gear
Clutches (5), (8) and (11) are engaged. The front planet gear carrier of gear set (9) is locked. Gear set (10) also rotates
as a solid block.
Gear position switch
The gear position switch outputs signals that are related to the position of the selector lever assembly. The switch is
installed on the selector shaft on the left side of the gearbox. Slotted mounting holes allow the switch to be turned
relative to the shaft for adjustment. A fly lead connects the switch to the vehicle wiring.
Movement of the selector lever assembly turns the selector shaft, which operates six pairs of contacts in the switch.
The pairs of contacts are identified as the W, X, Y, Z, Park/Neutral and Reverse contacts. When closed:
lThe W, X, Y and Z contacts output a 12V ignition supply from the BCU.
lThe Park/Neutral contacts output an earth.
lThe Reverse contacts output a 12V ignition supply from the passenger compartment fuse box.
The outputs of the W, X, Y and Z contacts are monitored by the EAT ECU and the BCU to determine the position of
the selector lever assembly.
Gear position switch W, X, Y, Z outputs
The Park/Neutral contacts output to the BCU and, on diesel models, the ECM. The Reverse contacts output to the
BCU, the reversing lamps, the SLABS ECU and, where fitted, the ACE ECU and the electrochromic interior mirror.
Switch
contactsOutput
PRND 3 2 1
W12V - 12V 12V - - -
X- 12V 12V - 12V - -
Y- - 12V 12V 12V - 12V
Z- - - 12V 12V 12V -

AUTOMATIC GEARBOX - ZF4HP22 - 24
DESCRIPTION AND OPERATION 44-17
Operation
Refer to illustration.

+ AUTOMATIC GEARBOX - ZF4HP22 - 24, DESCRIPTION AND OPERATION, Control schematic.
When the ignition is switched on, a bulb check is performed on the transmission temperature warning lamp and the
mode warning lamps by the instrument pack and the EAT ECU respectively. The warning lamps are illuminated for
approximately 3 seconds and then extinguished.
The gear position switch outputs are monitored by the BCU and the EAT ECU. The BCU outputs gear position signals
to illuminate the position indicators each side of the gear selector lever and on the odometer LCD in the instrument
pack.
In D, 3, 2, and 1, the EAT ECU outputs control signals to the gearbox to select the required gear.
In D, all forward gears are available for selection by the EAT ECU. In 3, 2 and 1, a corresponding limit is imposed on
the highest gear available for selection. When R is selected, reverse gear only engages if the vehicle is stationary or
moving at 5 mph (8 km/h) or less. When R is deselected, reverse gear only disengages if the vehicle is moving at 4
mph (6 km/h) or less.
Selector lever interlock (where fitted)
The interlock solenoid on the selector lever is de-energised unless the foot brake is applied while the ignition is on.
While de-energised, the interlock solenoid allows the selector lever to move through the range unless P is selected.
On entering the P position, the interlock solenoid engages a latch which locks the selector lever. When the ignition is
on and the foot brake is applied, the BCU energises the interlock solenoid, which disengages the latch and allows the
selector lever to be moved out of P.
Economy, sport and manual modes
During the power-up procedure after the ignition is switched on, the EAT ECU defaults to an economy mode. Pressing
the mode switch causes the EAT ECU to change between the economy mode and the sport or the manual mode,
depending on the range selected on the transfer box:
lIf the transfer box is in high range, the EAT ECU changes to the sport mode and illuminates the sport mode
warning lamp in the instrument pack. In the sport mode the gearbox is more responsive to accelerator pedal
movement. Downshifts occur earlier and upshifts occur later.
lIf the transfer box is in low range, the EAT ECU changes to the manual mode and illuminates the manual mode
warning lamp in the instrument pack. Kickdown is disabled and the EAT ECU maintains the gearbox in the gear
selected on the selector lever (D = 4th gear) to give improved off road performance. Downshifts occur only to
prevent the engine stalling. From a standing start, the vehicle pulls away in 1st gear and, if a higher gear is
selected, upshifts almost immediately to the selected gear (shifts of more than one gear can occur).
After a second press of the mode switch the EAT ECU reverts to the economy mode, for the range selected on the
transfer box, and extinguishes the related mode warning lamp in the instrument pack.
Shift control
To provide the different driving characteristics for each mode of operation, the EAT ECU incorporates different shift
maps of throttle position/engine speed. Base shift points are derived from the appropriate shift map. When a shift is
required, the EAT ECU sends a request to the ECM for a reduction in engine torque, in order to produce a smoother
shift. The percentage of torque reduction requested varies according to the operating conditions at the time of the
request. When the EAT ECU receives confirmation of the torque reduction from the ECM, it then signals the shift
solenoid valves in the gearbox to produce the shift. To further improve shift quality, the EAT ECU also signals the
pressure regulating solenoid valve to modulate the hydraulic pressure and so control the rate of engagement and
disengagement of the brake clutches.
With time, the components in a gearbox wear and the duration of the gear shifts tends to increase, which has an
adverse effect on the brake clutches. To counteract this, the EAT ECU applies a pressure adaptation to each shift.
To calculate the adaptations, the EAT ECU monitors the pressure modulation used, and time taken, for each shift. If
a subsequent shift of the same type, in terms of throttle position and engine speed, has a longer duration, the EAT
ECU stores an adaptation for that type of shift in a volatile memory. The adaptation is then included in future pressure
calculations for that type of shift, to restore shift duration to the nominal.

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-18 DESCRIPTION AND OPERATION
Kickdown
The EAT ECU monitors the input of the throttle position sensor to determine when kickdown is required. When it
detects a kickdown situation, the EAT ECU immediately initiates a down shift provided the target gear will not cause
the engine speed limit to be exceeded.
Torque converter lock-up
The EAT ECU energises the lock-up solenoid valve to engage the lock-up clutch. Lock-up clutch operation is
dependent on throttle position, engine speed, operating mode and the range selected on the transfer box.
High range
Unique lock-up maps, similar to the shift maps, are incorporated in the economy and sport modes for all forward gears.
Engagement and disengagement of the lock-up clutch is dependent on throttle position and engine speed.
Low range
To enhance off road control, particularly when manoeuvring at low speeds, torque converter lock-up does not occur
when there is any degree of throttle opening. When the throttle is closed above a preset engine speed, the lock-up
clutch engages to provide maximum engine braking.
Increased load/reduced torque compensation
To aid performance and driveability in the high range economy mode, the EAT ECU has three adaptive shift and lock-
up maps. These maps delay upshifts and torque converter lock-up similar to the sport mode if the inputs from the
engine indicate:
lA sustained high load on the engine, such as occurs when the vehicle is ascending a steep gradient or towing a
trailer.
lA lower than normal engine torque, such as occurs at altitude or high ambient temperatures.
The EAT ECU monitors the engine inputs and selects the most appropriate adaptive map for the prevailing conditions.
Diagnostics
While the ignition is on, the EAT ECU diagnoses the system for faults. The extent of the diagnostic capability at any
particular time depends on the prevailing operating conditions, e.g. it is not possible to check torque converter lock-
up while the vehicle is stationary, or to check for a short circuit to earth if the circuit concerned is already at a low
potential.
If a fault is detected, the EAT ECU immediately stores a fault code and the values of three operating parameters
associated with the fault. Depending on the fault, there are four possible effects:
lThe fault has little effect on gearbox operation or vehicle emissions. The driver will probably not notice any
change and the warning lamps remain extinguished.
lThe fault has little effect on gearbox operation but may effect vehicle emissions. On NAS vehicles, if the fault is
detected on a second consecutive drive cycle, the MIL illuminates.
lAll gears are available but kickdown does not function. The sport and manual warning lamps flash. The MIL
remains extinguished.
lLimp home mode is selected and vehicle performance is greatly reduced. The sport and manual warning lamps
flash. In all markets, if the fault is detected on a second consecutive drive cycle, the MIL illuminates.
After the detection of a fault, the effects remain active for the remainder of the drive cycle. In subsequent drive cycles,
as soon as the EAT ECU diagnoses the fault is no longer present, it resumes normal control of the gearbox. The
conditions required to diagnose that the fault is no longer present depend on the fault. Some faults require the engine
to be started, others require only that the ignition is switched on.
After a fault has not recurred for forty warm-up cycles, the fault is deleted from the EAT ECU memory. Only five
different faults can be stored in the memory at any one time. If a further fault occurs, the fault with the lowest priority
will be replaced by the new fault.
Mechanical limp home
In the mechanical limp home mode, gear engagement is controlled by the manual valve. The gearbox is fixed in 4th
gear if the fault occurs while the vehicle is moving, or 3rd gear if the fault occurs while the vehicle is stationary. 3rd
gear is also engaged if a vehicle is brought to a stop and the selector lever is moved out of, and back into, D. Neutral
and reverse gear are also available.