lock LAND ROVER DISCOVERY 2002 Workshop Manual

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-33
27.Remove 'C' clip securing selector cable to
gearbox bracket.
28.Remove nut securing selector lever to inhibitor
switch and release lever.
29.Disconnect multiplug from inhibitor switch.
30.Loosen gearbox multiplug locking ring and
disconnect plug.
31.Lower gearbox sufficiently to access bell
housing bolts, take care not to trap any pipes or
cables when lowering gearbox.
32.Remove 14 bolts securing gearbox to engine.
33.With assistance remove gearbox from engine.34.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.Position selector lever to inhibitor switch and
tighten nut to 25 Nm (18 lbf.ft).
8.Position selector cable to gearbox and secure
with 'C' clip.
9.Clean oil pipe unions and fit new 'O' rings.
10.Position and tighten pipe unions to gearbox.
11.Position and tighten oil cooler pipe clamps.
12.Position and tighten oil cooler pipe clip to
engine sump.
13.Position engine RH and LH rear mountings
and tighten bolts to 85 Nm (63 lbf.ft) and nuts to
85 Nm (63 lbf.ft).
14.Secure gearbox breather pipes to bulkhead
clip.
15.Connect multiplugs to high/low ratio switch and
neutral sensor. Connect Lucar connectors to
differential lock switch.
16.Position cable tie and multiplug to transfer
gearbox bracket.
17.Connect high/low ratio cable to transfer box
and secure with retaining clips.
18.Position hand brake back plate and tighten
bolts to 75 Nm (55 lbf.ft).
19.Fit hand brake drum and tighten screw.
20.Remove bolts securing tool LRT-99-008A to
gearbox.
21.Rotate engine to align torque converter, fit new
bolts and tighten to 50 Nm (37 lbf.ft).
22.Fit access plug to torque converter housing.
23.Fit rear propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-43
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.
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).
M44 1109B
97
8

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 44-51
Lock-up solenoid valve (MV 3)
$% 44.15.35
Remove
1.Remove valve body assembly.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Valve body assembly.
2.Disconnect multiplug from lock-up solenoid
valve and release harness from clip.
3.Remove Torx screw and retaining fork securing
solenoid valve to valve body.
4.Remove solenoid valve from valve body.
Refit
1.Clean lock-up solenoid valve with lint free cloth.
2.Position solenoid valve in valve body.
3.Position retaining fork, fit and tighten Torx
screw to 8 Nm (6 lbf.ft).
4.Connect multiplug to lock-up solenoid valve
and secure harness in clip.
5.Fit valve body assembly.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Valve body assembly.
Solenoids - shift control valves (MV 1 &
2)
$% 44.15.45
Remove
1.Remove valve body assembly.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Valve body assembly.
2.Remove 3 Torx screws securing lock-up
solenoid valve assembly to valve body and
move solenoid aside.
NOTE: This is to gain access to remove Torx
screw and MV2 shift control valve.
3.Note their fitted position and disconnect
multiplugs from shift control valves MV 1 and
MV 2.
4.Remove Torx screw and retaining fork securing
MV2 shift control solenoid valve to valve body.
Note that the tag on the retaining fork faces
towards the valve body.
5.Remove shift control valve from valve body.
M44 1354A
2
3
4
M44 13521
M44 1353A

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-52 REPAIRS
Refit
1.Clean MV2 shift control solenoid valve with lint
free cloth.
2.Position MV2 shift control solenoid valve to
valve body.
3.Position retaining fork, fit Torx screw and
tighten to 8 Nm (6 lbf.ft).
4.Connect multiplugs to both shift control
solenoid valves.
5.Clean lock-up solenoid valve assembly with a
lint-free cloth.
6.Position lock-up valve assembly, fit and tighten
Torx screws to 8 Nm (6 lbf.ft).
7.Fit valve body assembly.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Valve body assembly.
Harness - solenoid valves
$% 44.15.52
Remove
1.Remove valve body assembly.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Valve body assembly.
2.Release and remove clip securing pressure
regulator solenoid harness to valve body.
3.Disconnect multiplug from pressure regulator
solenoid valve.
4.Disconnect multiplugs from lock-up solenoid
valve, shift control solenoid valves MV 1 and
MV 2.
5.Release harness from 5 clips on valve body
and remove harness.
M44 1350
M44 1355

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
51-12 OVERHAUL
6.Ensure original head bearing shim is clean and
free from burrs and fit under bearing race.
7.Ensure pinion bearing cup recesses are clean
and free of burrs and using LRT-51-018-4 fit
pinion head and tail bearing races.
8.Fit pinion head bearing to pinion.
9.Lubricate bearings with thin oil.
10.Ensure original tail bearing shim is clean and
free from burrs and fit under bearing race.
11.Fit pinion and pinion tail bearing.
12.Fit pinion flange, washer and bolt.
13.Use LRT-51-003 to restrain pinion flange.
14.Tighten pinion flange bolt to 100 Nm (74 lbf.ft).
15.Check pinion for end float. Should read zero.
16.Rotate pinion several times to settle bearings,
check pinion Torque to Turn. Torque to Turn
should be recorded during pinion rotation.
Pinion Torque to Turn should be 4 to 6 Nm (3 to
4.5 lbf.ft).
17.Adjust size of tail bearing shim to obtain correct
pinion Torque to Turn (0.025 mm = 1 Nm
(0.001' = 0.7 lbf.ft) approximately).
18.Position LRT-51-018-7 on surface plate,
establish zero and reference DTI.19.Ensure pinion height setting block, setting
gauge and mating faces are clean and free
from burrs.
20.Locate setting block LRT-51-018/11 over
pinion head, ensure it is fully seated in position.
21. Pinion height setting procedure:
l'A' = Nominal pinion height setting, 74.390.
l'B' = Setting block height.
l'C' = Head height setting.
l'C' = 'A' - 'B'. Subtract nominal pinion height
'A' from setting block height 'B' (on side of
setting block).
lExample: 74.390 - 73.130 = 1.26 mm
(2.929' - 2.88' = 0.049'). Therefore pinion
head height reading is 1.260 mm
± 0.025
mm (0.049'
± 0.001').
CAUTION: Setting block height must be
checked using figures on side of block.

REAR AXLE
OVERHAUL 51-13
22.Align setting gauge LRT-51-018/7 to setting
block, rock gauge to obtain minimum reading. If
reading is lower than required reading,
decrease shim size. If reading is higher than
required reading, increase shim size.
23.Using LRT-51-003 to restrain pinion flange,
remove bolt and washer. Remove pinion
flange.
24.Remove pinion, collect tail bearing and tail
bearing shim.
25.Remove pinion head bearing outer race and
shim. Discard shim. Ensure bearing race
recess is clean and free from burrs.
26.Fit calculated shim, and using LRT-51-018/4 fit
head bearing outer race.
27.Fit pinion, pinion tail bearing and tail bearing
shim.
28.Fit pinion flange and bolt and washer. Using
LRT-51-003 to restrain pinion flange, tighten
bolt to 100 Nm (74 lbf.ft).
29.Rotate pinion in both directions to settle
bearings.
30.Recheck pinion Torque to Turn, adjust if
necessary.
31.Recheck pinion head height.
32.Using LRT-51-003 to restrain pinion flange,
remove bolt and washer. Remove pinion
flange.
33.Discard bolt.34.Using LRT-51-010 fit pinion seal.
35.Ensure spacer and tail bearing are correctly
located.
36.Fit pinion, pinion flange and washer.
37.Fit new pinion flange bolt and tighten to 100 Nm
(74 lbf.ft).
38.Lightly oil differential bearings.
39.Ensure spring dowels are fitted in bearing caps.
40.Fit differential bearing outer races and locate
differential assembly into housing.
41.Fit bearing caps and tighten bolts to 10 Nm (7.5
lbf.ft).
42.Fit adjusting nuts, tighten crown wheel side nut
to 22 Nm (16 lbf.ft). Ensure opposing nut is
loose.
43.Position DTI to check crown wheel backlash.
Adjust opposing nut to obtain correct crown
wheel backlash.
44.Rotate pinion in both directions to settle
bearings.
45.Measure in 3 places to obtain correct crown
wheel backlash.
NOTE: Crown wheel backlash should be within
0.076 mm - 0.177 mm (0.003' - 0.007').
46.Align adjusting nuts to next roll pin slot, do not
loosen nuts to align slots.

STEERING
DESCRIPTION AND OPERATION 57-3
1Air bag module
2Steering wheel and nut
3Horn switch 2 off
4Radio remote control switch (if fitted)
5Column switches
6Lower nacelle
7Column tilt adjustment lever
8Steering column lock
9Ignition switch and harness
10Upper column assembly
11Lower column
12Universal joint 13Bolt
14Bolt
15Intermediate shaft assembly
16Decouple joint
17Rubber coupling and heat shield
18Bolt
19Universal joint
20Shear bolt 2 off
21Rotary coupler
22Upper nacelle
23Cruise control switch (if fitted)