gearbox LAND ROVER DISCOVERY 1999 Workshop Manual

CONTENTS
CONTENTS 1
INTRODUCTION ...................................................................................... 01-1
How To Use This Manual................................................................................................................ 01-1
Repairs and Replacements ............................................................................................................. 01-2
Specifications .................................................................................................................................. 01-2
Abbreviations and Symbols ............................................................................................................ 01-3
GENERAL INFORMATION ...................................................................... 03-1
General Precautions ....................................................................................................................... 03-1
Safety Instructions .......................................................................................................................... 03-2
Environmental Precautions ............................................................................................................. 03-3
General Fitting Instructions ............................................................................................................. 03-6
Ball and Roller Bearings ................................................................................................................. 03-7
Oil Seals.......................................................................................................................................... 03-8
Joints and Joint Faces .................................................................................................................... 03-9
Locking Devices .............................................................................................................................. 03-9
Screw Threads ................................................................................................................................ 03-10
Bolt and Nut Identification ............................................................................................................... 03-11
Flexible Pipes and Hoses ............................................................................................................... 03-13
Rolling Road Testing....................................................................................................................... 03-15
Fuel Handling Precautions .............................................................................................................. 03-16
Electrical Precautions ..................................................................................................................... 03-17
Supplementary Restraint System Precautions ............................................................................... 03-18
SRS Component Replacement Policy ............................................................................................ 03-23
Air Conditioning System Precautions .............................................................................................. 03-24
Air Conditioning Compressor Replacement .................................................................................... 03-26
Body Repairs .................................................................................................................................. 03-27
GENERAL DATA ..................................................................................... 04-1
Engine - Td5 ................................................................................................................................... 04-1
Engine - V8 ..................................................................................................................................... 04-4
Fuel system - Td5 ........................................................................................................................... 04-8
Fuel system - V8 ............................................................................................................................. 04-8
Cooling system - Td5 ...................................................................................................................... 04-9
Cooling system - V8 ........................................................................................................................ 04-10
Clutch - Td5 .................................................................................................................................... 04-11
Clutch - V8 ...................................................................................................................................... 04-12
Manual gearbox - R380 .................................................................................................................. 04-13
Transfer box - LT230SE .................................................................................................................. 04-14
Automatic gearbox - ZF4HP22/24 .................................................................................................. 04-15
Rear axle......................................................................................................................................... 04-16
Front axle ........................................................................................................................................ 04-16
Steering........................................................................................................................................... 04-17
Suspension ..................................................................................................................................... 04-18
Brakes ............................................................................................................................................. 04-19
Wheels and tyres ............................................................................................................................ 04-20
Air conditioning ............................................................................................................................... 04-21
Electrical - Td5 ................................................................................................................................ 04-22
Electrical - V8 .................................................................................................................................. 04-22
Dimensions ..................................................................................................................................... 04-23
Weights ........................................................................................................................................... 04-24

CONTENTS
2CONTENTS
IDENTIFICATION NUMBERS .................................................................. 05-1
Vehicle Identification Number ......................................................................................................... 05-1
Identification Number Locations ..................................................................................................... 05-3
TORQUE WRENCH SETTINGS .............................................................. 06-1
Maintenance ................................................................................................................................... 06-1
Engine Td5 ..................................................................................................................................... 06-2
Engine V8 ....................................................................................................................................... 06-4
Emission control - Td5 .................................................................................................................... 06-5
Emission control - V8 ...................................................................................................................... 06-5
Engine management system - Td5 ................................................................................................. 06-6
Engine management system - V8................................................................................................... 06-6
Cooling system ............................................................................................................................... 06-7
Manifolds and exhaust systems - Td5 ............................................................................................ 06-8
Manifolds and exhaust systems - V8 .............................................................................................. 06-8
Clutch.............................................................................................................................................. 06-9
Manual gearbox - R380 .................................................................................................................. 06-10
Transfer box - LT230SE ................................................................................................................. 06-11
Automatic gearbox - ZF4HP22 ....................................................................................................... 06-12
Propeller shafts ............................................................................................................................... 06-13
Axles ............................................................................................................................................... 06-13
Steering .......................................................................................................................................... 06-14
Front suspension ............................................................................................................................ 06-15
Rear suspension ............................................................................................................................. 06-16
Brakes............................................................................................................................................. 06-17
Restraint systems ........................................................................................................................... 06-18
Body................................................................................................................................................ 06-19
Heating and air conditioning ........................................................................................................... 06-20
Wipers and washers ....................................................................................................................... 06-20
Electrical ......................................................................................................................................... 06-21
LIFTING AND TOWING ........................................................................... 08-1
LIFTING .......................................................................................................................................... 08-1
TOWING ......................................................................................................................................... 08-2
TRANSPORTING ........................................................................................................................... 08-4
CAPACITIES, FLUIDS, LUBRICANTS AND SEALANTS ...................... 09-1
Capacities ....................................................................................................................................... 09-1
Fluids .............................................................................................................................................. 09-2
Anti-Freeze Concentration .............................................................................................................. 09-2
Lubrication ...................................................................................................................................... 09-3
Sealants .......................................................................................................................................... 09-4

CONTENTS
CONTENTS 3
MAINTENANCE ........................................................................................ 10-1
PROCEDURES
V8 engine underbonnet view .......................................................................................................... 10-1
Diesel underbonnet view ................................................................................................................. 10-2
Seats and seat belts ...................................................................................................................... 10-3
Lamps, horns and warning indicators ............................................................................................. 10-5
Wipers and washers ...................................................................................................................... 10-5
Handbrake .................................................................................................................................. 10-6
Alarm handset battery ..................................................................................................................... 10-6
Road wheels ................................................................................................................................... 10-6
Tyres .............................................................................................................................................. 10-6
Brake pads, discs and calipers ....................................................................................................... 10-6
Road wheel speed sensors ............................................................................................................. 10-7
Brake fluid ....................................................................................................................................... 10-7
Fuel filter - diesel engine ................................................................................................................. 10-7
Fuel filter sedimenter ...................................................................................................................... 10-7
Road wheels ................................................................................................................................... 10-8
Radiator/Intercooler ........................................................................................................................ 10-8
Ambient air Temperature and pressure sensor .............................................................................. 10-8
Doors, bonnet and fuel filler flap ..................................................................................................... 10-8
Air suspension intake filter .............................................................................................................. 10-9
Anti-freeze....................................................................................................................................... 10-9
Cooling system ............................................................................................................................... 10-9
Spark plugs - V8 engine.................................................................................................................. 10-10
Air cleaner - V8 engine ................................................................................................................... 10-10
Air cleaner and dump valve - diesel engine .................................................................................... 10-10
Auxiliary drive belt ........................................................................................................................... 10-11
Auxiliary drive belt - V8 engine ....................................................................................................... 10-11
Auxiliary drive belt - diesel engine .................................................................................................. 10-11
Fluid reservoirs ............................................................................................................................... 10-12
Steering box .................................................................................................................................... 10-13
Battery ............................................................................................................................................. 10-13
Intercooler - diesel engine............................................................................................................... 10-14
Engine oil - V8 engine ..................................................................................................................... 10-14
Engine oil - diesel engine ................................................................................................................ 10-15
Centrifuge rotor – diesel engine ...................................................................................................... 10-15
Engine oil filter - diesel engine ........................................................................................................ 10-16
Engine oil filter – V8 engine ............................................................................................................ 10-16
Manual gearbox .............................................................................................................................. 10-17
Automatic gearbox ......................................................................................................................... 10-18
Transfer box .................................................................................................................................... 10-19
Front and rear axle .......................................................................................................................... 10-20
Propeller shafts ............................................................................................................................... 10-20
Anti-roll bar links ............................................................................................................................. 10-22
ACE actuators ................................................................................................................................. 10-23
ACE filter ......................................................................................................................................... 10-23

CONTENTS
4CONTENTS
Brake hose, brake, fuel, ACE, clutch pipes and unions/electrical harnesses ................................ 10-24
Engine, gearbox, transfer box and axles ........................................................................................ 10-25
Exhaust system .............................................................................................................................. 10-25
Steering box and front suspension ................................................................................................. 10-25
Steering rod ball joints ................................................................................................................... 10-27
Dampers and SLS height sensors .................................................................................................. 10-27
Front and rear axle suspension links .............................................................................................. 10-28
Towing bracket ............................................................................................................................... 10-29
Engine mountings - V8 engine........................................................................................................ 10-30
Road/roller test ............................................................................................................................... 10-31

CONTENTS
10 CONTENTS
MANUAL GEARBOX - R380 .................................................................... 37-1
DESCRIPTION AND OPERATION
R380 gearbox ................................................................................................................................. 37-1
Gearbox casings, gear change and oil pump ................................................................................ 37-2
Selector shaft and forks, synchromesh assemblies and gear train ............................................... 37-4
R380 gearbox cross section ........................................................................................................... 37-6
Description ...................................................................................................................................... 37-7
Operation ........................................................................................................................................ 37-8
ADJUSTMENTS
Spring - gear lever bias .................................................................................................................. 37-9
REPAIRS
Housing - gear selector .................................................................................................................. 37-11
Gearbox - V8 .................................................................................................................................. 37-12
Gearbox - Diesel ............................................................................................................................. 37-16
Seal - gearbox mainshaft ............................................................................................................... 37-20
Seal - input shaft ............................................................................................................................ 37-21
Cooler - oil - gearbox - Diesel ......................................................................................................... 37-23
Cooler - oil - gearbox - V8............................................................................................................... 37-24
Switch - Reverse light ................................................................................................................... 37-25
OVERHAUL
Shaft - output ................................................................................................................................. 37-27
Synchroniser - gearbox - set ......................................................................................................... 37-32
Fork - set - selector shaft .............................................................................................................. 37-34
Shaft - gearbox - input .................................................................................................................. 37-35
Extension - gearbox rear ............................................................................................................... 37-38
Pump - gearbox oil ......................................................................................................................... 37-41
Filter - gearbox oil ......................................................................................................................... 37-41
Gear - 5th gear set ........................................................................................................................ 37-42
Synchronizer assembly - 5th/reverse ........................................................................................... 37-43
5th gear - layshaft ......................................................................................................................... 37-44
Bearing - layshaft rear support ..................................................................................................... 37-46
Bearing - output shaft rear support ............................................................................................... 37-47
Shaft - reverse idler ...................................................................................................................... 37-48
Housing - gear selector mechanism ............................................................................................. 37-50
Lever - gear change ...................................................................................................................... 37-51
Housing - clutch ............................................................................................................................ 37-52
Cover - front ................................................................................................................................... 37-53

CONTENTS
12 CONTENTS
AUTOMATIC GEARBOX - ZF4HP22 - 24 ................................................ 44-1
DESCRIPTION AND OPERATION
Automatic gearbox component layout ............................................................................................ 44-1
Control schematic ........................................................................................................................... 44-2
Description ...................................................................................................................................... 44-4
Operation ........................................................................................................................................ 44-17
ADJUSTMENTS
Cable - selector ............................................................................................................................. 44-21
Stall test .......................................................................................................................................... 44-21
REPAIRS
Cable and lever assembly - selector .............................................................................................. 44-23
Selector indicator .......................................................................................................................... 44-24
Switch - starter inhibitor ................................................................................................................. 44-25
Seal - selector shaft ........................................................................................................................ 44-26
Gearbox - convertor and transfer gearbox - Diesel ....................................................................... 44-27
Gearbox - convertor and transfer gearbox - V8 ............................................................................ 44-32
Torque converter and oil seal ......................................................................................................... 44-37
Housing - torque converter ............................................................................................................ 44-38
Gasket - intermediate plate ............................................................................................................ 44-39
Intermediate plate .......................................................................................................................... 44-41
Pump - fluid .................................................................................................................................... 44-43
Seal - rear extension housing ......................................................................................................... 44-44
Gasket - rear extension housing. .................................................................................................. 44-45
Parking pawl assembly. ................................................................................................................ 44-46
Gasket - oil sump ........................................................................................................................... 44-47
Filter - oil ........................................................................................................................................ 44-48
Cooler - fluid - Td5 .......................................................................................................................... 44-49
Cooler - fluid - V8 ........................................................................................................................... 44-50
Valve body assembly ..................................................................................................................... 44-51
Seal - valve body ........................................................................................................................... 44-53
Pressure regulator ......................................................................................................................... 44-54
Lock-up solenoid valve (MV 3) ...................................................................................................... 44-55
Solenoids - shift control valves
(MV 1 & 2) 44-56
Harness - solenoid valves .............................................................................................................. 44-57
Electronic control unit - automatic transmission ............................................................................. 44-58
PROPELLER SHAFTS ............................................................................. 47-1
DESCRIPTION AND OPERATION
Propeller shaft component layout ................................................................................................... 47-1
Description ...................................................................................................................................... 47-2
REPAIRS
Propeller shaft - front ..................................................................................................................... 47-5
Propeller shaft - rear ...................................................................................................................... 47-5
Bush - spigot - rear propeller shaft ................................................................................................ 47-6
Flexible coupling ............................................................................................................................ 47-7
OVERHAUL
Propeller shaft................................................................................................................................. 47-9

INTRODUCTION
01-1
INTRODUCTION
How To Use This Manual
Introduction
This Manual is designed to assist skilled technicians
in the efficient repair and maintenance of Discovery
vehicles.
Individuals who undertake their own repairs should
have some skill and training, and limit repairs to
components which could not affect the safety of the
vehicle or its passengers. Any repairs required to
safety critical items such as steering, brakes,
suspension or supplementary restraint system
should be carried out by a Land Rover Dealer.
Repairs to such items should NEVER be attempted
by untrained individuals.
General
To assist in the use of this Manual, it is divided into
sections and sub-sections. The section title is given
at the top of each page and the relevant sub-section
is given at the bottom.
There is a single contents section at the front of the
Manual, which is divided by section and sub-section.
Each section is numbered from page 1.
The individual items comprising repair operations are
to be followed in the sequence in which they appear.
Items numbers in the illustration are referred to in the
text.
Adjustment and Repair operations include reference
to Service tool numbers and the associated
illustration depicts the tool in use. Adjustment and
repair operations also include reference to wear
limits, relevant data, torque figures, and specialist
information and useful assembly details. Each
adjustment or repair operation is given its Service
Repair Operation number.
WARNINGS, CAUTIONS and NOTES have the
following meanings:
WARNING: Procedures which must be followed
precisely to avoid the possibility of injury.
CAUTION: Calls attention to procedures which
must be followed to avoid damage to
components.
NOTE: Gives helpful information.References
References to the LH or RH side given in this Manual
are made when viewing the vehicle from the rear.
With the engine and gearbox assembly removed, the
crankshaft pulley end of the engine is referred to as
the front.
Operations covered in this Manual do not include
reference to testing the vehicle after repair. It is
essential that work is inspected and tested after
completion and if necessary a road test of the vehicle
is carried out particularly where safety related items
are concerned.
Dimensions
The dimensions quoted are to design engineering
specification with Service limits where applicable.

GENERAL INFORMATION
03-15
Hose clips
Markings (4) are usually provided on the hose to
indicate the correct clip position. If no markings are
provided, position the clip directly behind the
retaining lip at the end of the stub as shown. Worm
drive clips should be oriented with the crimped side
of the drive housing (5) facing towards the end of the
hose, or the hose may become pinched between the
clip and the stub pipe retaining lip. Worm drive clips
should be tightened to 3 Nm (2 lbf.ft) unless
otherwise stated. Ensure that hose clips do not foul
adjacent components.
Heat protection
Always ensure that heatshields and protective
sheathing are in good condition. Replace if damage
is evident. Particular care must be taken when
routing hoses close to hot engine components, such
as the exhaust manifold and the Exhaust Gas
Recirculation (EGR) pipe. Hoses will relax and
deflect slightly when hot; ensure this movement is
taken into account when routing and securing hoses.
Rolling Road Testing
General
IMPORTANT: Use a four wheel rolling road for
brake testing if possible.
WARNING: Do not attempt to test ABS function
on a rolling road.
Four wheel rolling road
Provided that front and rear rollers are rotating at
identical speeds and that normal workshop safety
standards are applied, there is no speed restriction
during testing except any that may apply to the tyres.
Before testing a vehicle with anti-lock brakes on a
four wheel rolling road, disconnect the ABS
modulator. The ABS function will not work, the ABS
warning light will illuminate. Normal braking will be
available.
Two wheel rolling road
Up to 03MY
ABS will not function on a two wheel rolling road. The
ABS light will illuminate during testing. Normal
braking will be available.
If brake testing on a two wheel rolling road is
necessary, the following precautions should be
taken:
lPropeller shaft to the rear axle is removed.
lNeutral selected in gearbox.
When checking brakes, run engine at idle speed to
maintain servo vacuum.
From 03MY
The differential lock must be engaged for two wheel
rolling road testing. It will also be necessary to
disconnect the propeller shaft from the transfer box
output shaft driving the axle whose wheels are NOT
on the rolling road. Additionally, the ETC system
must be deactivated by either removing the 10 amp
fuse (Number 28, labelled ABS in the main fuse box)
or disconnecting the ABS modulator pump. This
must be done with the ignition OFF ; a fault in the
ABS system may still be recorded.
WARNING; VEHICLES NOT FITTED WITH A
DIFFERENTIAL LOCK MUST NOT BE TESTED
ON A ROLLING ROAD WHERE THE ROLLERS
ARE DRIVEN BY THE VEHICLE.

GENERAL DATA
04-1
GENERAL DATA
Engine - Td5
General
Type 2.5 litre in-line direct injection diesel, turbocharged and intercooled
Cylinder arrangement 5 in-line, No. 1 cylinder at front of engine
Bore 84.450 mm (3.3248 in)
Stroke 88.950 mm (3.5020 in)
Capacity 2498 cm
3 (152.5 in3)
Firing order 1 - 2 - 4 - 5 - 3
Compression ratio 19.5 : 1
Direction of rotation Clockwise viewed from the front of the engine
Dimensions:
⇒ Length 766 mm (30.1 in)
⇒ Width 708 mm (27.8 in)
⇒ Height 788 mm (31.0 in)
Injection timing Controlled by ECM
Injectors:
⇒ Make/Type Lucas EV1/Dual stage
⇒ Injector operating pressures:
Pre EU3 models:
⇒ Initial opening pressure 270 bar (3915 lbf.in
2)
⇒ Fully opened pressure 440 bar (6380 lbf.in
2)
⇒ Maximum pressure 1560 bar (22620 lbf.in
2)
EU3 models:
⇒ Initial opening pressure 270 bar (3915 lbf.in
2)
⇒ Fully opened pressure 440 bar (6380 lbf.in
2)
⇒ Maximum pressure 1750 bar (25375 lbf.in
2)
Maximum governed speed 4850 rev/min
Maximum overrun speed 5460 rev/min
Idle speed:
⇒ Manual gearbox 740 ± 50 rev/min
⇒ Automatic gearbox 760 ± 50 rev/min
Glow plugs Beru 12 V. Four plugs in cylinders 1, 2, 3 and 4
Turbocharger Garrett GT 20
Emissions standard:
⇒ Pre EU3 models ECD 2
⇒ EU3 models ECD 3
Valve timing
Inlet valves:
⇒ Opens 14° BTDC
⇒ Closes 33° ABDC
Exhaust valves:
⇒ Opens 57° BBDC
⇒ Closes 14° ATDC

GENERAL DATA
04-13
Manual gearbox - R380
Type Single helical constant mesh
Gears 5 forward, 1 reverse, all synchromesh
Gear ratios: Td5 Diesel
⇒ First 3.692 : 1
⇒ Second 2.132 : 1
⇒ Third 1.397 : 1
⇒ Fourth 1.0 : 1
⇒ Fifth 0.770 : 1
⇒ Reverse 3.536 : 1
Gear ratios: V8 Petrol
⇒ First 3.321:1
⇒ Second 2.132:1
⇒ Third 1.397:1
⇒ Fourth 1.0:1
⇒ Fifth 0.732:1
⇒ Reverse 3.536:1
Baulk ring clearance:
⇒ New 0.500 mm (0.0197 in)
⇒ Service limit 0.500 mm (0.0197 in)
⇒ Selector fork pad widths - minimum 6.5 mm (0.255 in)
First gear end float:
⇒ New 0.050 - 0.200 mm (0.0020 - 0.0079 in)
⇒ Service limit 0.327 mm (0.0129 in)
Second gear end float:
⇒ New 0.040 - 0.210 mm (0.0016 - 0.0083 in)
⇒ Service limit 0.337 mm (0.0133 in)
Third gear end float:
⇒ New 0.110 - 0.210 mm (0.0043 - 0.0083 in)
⇒ Service limit 0.337 mm (0.0133 in)
Adjust fifth / reverse hub - shim to
⇒ New 0.005 - 0.055 mm (0.0002 - 0.0022 in)
⇒ Service limit 0.055 mm (0.0022 in)
Reverse gear idler shaft clearance
⇒ New 0.040 - 0.380 mm (0.0016 - 0.0150 in)
⇒ Service limit 0.380 mm (0.0150 in)
Mainshaft end float:
⇒ New 0.000 - 0.050 mm (0.0000 - 0.0020 in)
⇒ Service limit 0.000 - 0.050 mm (0.0000 - 0.0020 in)
Layshaft end float:
⇒ New 0.000 - 0.050 mm (0.0000 - 0.0020 in)
⇒ Service limit 0.000 - 0.050 mm (0.0000 - 0.0020 in)