sensor LAND ROVER DISCOVERY 2002 Workshop Manual

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-47
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.
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.

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-48 REPAIRS
5.Remove 6 long bolts securing valve body to
gearbox.
6.Remove 5 short bolts securing valve body to
gearbox.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
6.Disconnect and remove speed sensor from
harness.
Refit
1.Connect speed sensor to harness multiplug.
2.Position harness to valve body.
3.Connect multiplugs to shift control solenoid
valves MV 1 and MV 2 and lock-up solenoid
valve.
4.Connect multiplug to pressure regulator
solenoid valve and secure solenoid valve
harness with clip to valve body.
5.Position and secure harness in clips on valve
body.
6.Fit valve body assembly.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Valve body assembly.
Electronic control unit - automatic
transmission
$% 44.15.46
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery earth lead.
3.Remove 3 screws and trim clip securing lower
trim casing to LH front seat.
4.Remove 3 nuts securing speaker power
amplifier bracket to the body.
5.Disconnect multiplug from automatic
transmission ECU located on underside of
amplifier mounting bracket.
M44 1359

REAR AXLE
DESCRIPTION AND OPERATION 51-3
Wheel hub
Section through wheel hub
1'O' ring
2Hub bearing
3Hub flange
4Wheel stud5Stake nut
6ABS sensor ring
7Drive shaft
8Axle casing
Each wheel hub consists of a hub flange pressed into a hub bearing.
The hub flange is splined to accept the outboard end of the drive shaft, which is secured to the hub flange with a stake
nut. Five studs are installed in the hub flange for the wheel nuts, and a threaded hole is provided for the brake disc
securing screw.
The outer race of the hub bearing is bolted to the end of the axle casing. An 'O' ring seals the joint between the outer
race and the axle casing to prevent leakage of differential lubricating oil. The hub bearing is a sealed unit which
contains twin opposed roller bearings, pre-packed with grease during manufacture. A toothed ABS sensor ring is
integrated into the inner race of the hub bearing. An opening in the outer race of the hub bearing accommodates the
ABS sensor.
Drive shaft
Each drive shaft consists of a solid rod, splined at both ends.

REAR AXLE
REPAIRS 51-5
REPAIRS
Differential - assembly
$% 51.15.01
Remove
1.Raise rear of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Drain oil from differential.

+ MAINTENANCE, PROCEDURES,
Front and rear axle.
3.If same components are to be refitted,
reference mark propeller shaft and mating
components.
4.Remove 3 nuts and bolts securing flexible
coupling to pinion flange. Release propeller
shaft and tie aside.
5.Using tool LRT-51-008, extract the centralising
peg from the pinion flange. Remove the
centralising peg from the tool.6.Remove LH and RH rear brake discs.

+ BRAKES, REPAIRS, Brake disc -
rear.
7.Disconnect each ABS sensor multiplug.
8.Release each harness from brake hose and
hose bracket.
9.Remove 4 bolts securing each rear wheel hub
to rear axle.
M51 0041B
5
4
M51 0056
LRT-51-008

REAR AXLE
51-6 REPAIRS
10.Release and remove wheel hubs and drive
shafts from rear axle. Remove and discard 'O'
rings from wheel hubs.
11.Remove 10 bolts securing differential to axle.
Release and remove differential from axle. Refit
1.Clean drive shafts, wheel hubs and wheel hub
locations in rear axle.
2.Using a suitable solvent, clean old RTV sealant
from differential and axle mating faces.
3.Apply RTV sealant to differential or axle mating
face.
4.Apply Loctite 243 to threads of differential
securing bolts.
5.Fit differential to axle, fit bolts and tighten to 55
Nm (41 lbf.ft).
6.Clean pinion flange and centralising peg.
7.Using a tubular drift, fit centralising peg to
pinion flange. Ensure that the large diameter
part of the centralising peg is below pinion
flange mounting surface.
8.Position propeller shaft and align reference
marks.
9.Fit nuts and bolts securing flexible coupling to
pinion flange and tighten to 76 Nm (56 lbf.ft)
10.Lubricate 2 new wheel hub 'O' rings with clean
differential oil.

+ CAPACITIES, FLUIDS AND
LUBRICANTS, Lubrication. Install 'O' rings on
wheel hubs.
11.Fit LH and RH drive shafts and wheel hubs to
rear axle. Fit wheel hub bolts and tighten to 100
Nm (74 lbf.ft).
12.Connect each ABS sensor multiplug and
secure harness to harness bracket and brake
hose.
13.Fit LH and RH rear brake discs.

+ BRAKES, REPAIRS, Brake disc -
rear.
14.Remove stand(s) and lower vehicle.
15.Fill differential with oil.

+ MAINTENANCE, PROCEDURES,
Front and rear axle.
M51 0042B

FRONT AXLE
DESCRIPTION AND OPERATION 54-3
Wheel hub
Section through wheel hub
1Drive shaft
2Axle casing
3Gaiter
4Upper ball joint
5Constant velocity joint
6Steering knuckle
7Hub bearing
8Hub flange9Wheel stud
10Stake nut
11ABS sensor ring
12Tension collet
13Lower ball joint
14Securing bands
15Shield
16Oil seal
Each wheel hub consists of a hub flange pressed into a hub bearing.
The hub flange is splined to accept the constant velocity joint of the drive shaft, which is secured to the hub flange
with a stake nut. Five studs are installed in the hub flange for the wheel nuts and a threaded hole is provided for the
brake disc securing screw.
The outer race of the hub bearing is bolted to the steering knuckle. The hub bearing is a sealed unit which contains
twin opposed roller bearings, pre-packed with grease during manufacture. A toothed ABS sensor ring is integrated
into the inner race of the hub bearing. An opening in the outer race of the hub bearing accommodates the ABS sensor.

FRONT AXLE
REPAIRS 54-5
REPAIRS
Differential - assembly
$% 54.10.01
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove front road wheels.
3.Drain oil from differential.

+ MAINTENANCE, PROCEDURES,
Front and rear axle.
4.If same components to be refitted, reference
mark propeller shaft and mating components.
5.Remove 4 nuts and bolts securing propeller
shaft to differential. Release propeller shaft and
tie aside.
6.Remove LH and RH front brake discs.

+ BRAKES, REPAIRS, Brake disc -
front.7.Disconnect each ABS sensor multiplug.
8.Release each harness from brake hose and
hose bracket.

FRONT AXLE
54-6 REPAIRS
9.Remove 4 bolts securing each front wheel hub
to front axle.
10.Release wheel hubs from front axle. Remove
wheel hubs and drive shafts from front axle.
11.Remove oil seal from axle casing.
12.Remove 10 bolts securing differential to axle
casing. Release and remove differential from
axle casing.Refit
1.Clean drive shaft oil seal recess, oil seal
running surface, wheel hub and axle mating
faces.
2.Using a suitable solvent, clean old RTV sealant
from differential and axle mating faces.
3.Apply RTV sealant to differential or axle mating
face.
4.Apply Loctite 243 to threads of differential
securing bolts.
5.Fit differential to axle, fit bolts and tighten to 55
Nm (41 lbf.ft).
6.Position propeller shaft and align reference
marks. Fit bolts and tighten to 47 Nm (35 lbf.ft).
7.Lubricate oil seal lip and running surface with
clean differential oil.
+ CAPACITIES, FLUIDS AND
LUBRICANTS, Lubrication.
8.Using LRT-54-012 and LRT-99-003, fit new
drive shaft oil seal to axle casing.
9.Apply anti-seize compound to wheel hub and
steering knuckle mating faces.
10.Ensure ABS harnesses are located in cut out in
steering knuckles.
11.Fit drive shafts in axle casing and align wheel
hubs with steering knuckles. Fit wheel hub bolts
and tighten to 100 Nm (74 lbf.ft).
12.Connect each ABS sensor multiplug and
secure harness to harness bracket and brake
hose.

FRONT AXLE
REPAIRS 54-9
Seal - oil - front axle casing
$% 54.15.04
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove road wheel.
3.Remove front brake disc.

+ BRAKES, REPAIRS, Brake disc -
front.
4.Disconnect ABS sensor multiplug.5.Release harness from brake hose and hose
bracket.
6.Remove 4 bolts securing wheel hub to steering
knuckle.
7.Release wheel hub from steering knuckle.
8.Remove wheel hub and drive shaft from axle.