check oil LAND ROVER DISCOVERY 2002 Repair Manual

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-30 REPAIRS
14.Secure gearbox breather pipes to bulkhead
clip.
15.Connect multiplugs to high/low ratio switch and
neutral sensor. Connect Lucars to differential
lock switch.
16.Position cable tie and multi plug to transfer box
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 rear propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.
23.Fit front propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
24.Fill transfer gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
25.Fill automatic gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
26.Position intermediate silencer and secure to
mounting rubbers.
27.Clean silencer and tail pipe mating faces.
28.Position new gasket to tail pipe and tighten
nuts to 25 Nm (18 lbf.ft).
29.Fit exhaust front pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - Td5, REPAIRS, Pipe - front.
30.Fit bolt securing closing plate to gearbox
housing and tighten to 7 Nm (5.2 lbf.ft).
31.Fit upper bolts securing gearbox housing to
engine and tighten to 50 Nm (37 lbf.ft).
32.Fit starter motor.

+ CHARGING AND STARTING,
REPAIRS, Starter motor - diesel.
33.Tighten remaining gearbox housing to engine
bolts to 50 Nm (37 lbf.ft).
34.Connect battery earth lead.
35.Fit battery cover and secure with fixings.
36.Check and adjust selector cable.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, ADJUSTMENTS, Cable - selector.
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.

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-34 REPAIRS
24.Fit front propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
25.Fill transfer gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
26.Fill automatic gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
27.Position intermediate silencer and secure to
mounting rubbers.
28.Clean silencer and tail pipe mating faces.
29.Position new gasket to tail pipe and tighten nuts
to 40 Nm (30 lbf.ft).
30.Fit exhaust front pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Front pipe.
31.Position centre cross member, fit bolts and
tighten to 26 Nm (19 lbf.ft).
32.Connect battery earth lead.
33.Fit battery cover and secure fixings.
34.Check and adjust selector cable.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, ADJUSTMENTS, Cable - selector.
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.

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-36 REPAIRS
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 High Formular Hylomar sealant 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 (34lbf. 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.
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.
M44 1343
M44 1358
LRT-44-003/1

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-38 REPAIRS
11.Mount DTI gauge and position gauge probe
onto LRT-44-003/1 and zero gauge.
12.Check that the axial end-float is between 0.2 to
0.4 mm (0.008 to 0.016 in). If end-float in 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.
Intermediate plate
$% 44.17.20
Remove
1.Remove intermediate plate gasket.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Gasket - intermediate plate.
2.Remove selective thrust washer from
intermediate plate.
3.Remove 2 M14 Allen plugs from intermediate
plate, remove and discard sealing washers.
4.Remove 2 M20 plugs from intermediate plate,
remove and discard sealing washers.
5.Remove 2 oil cooler pipe adaptors from
intermediate plate.
6.Remove 8 bolts securing fluid pump to
intermediate plate and carefully remove pump
from intermediate plate.
2443
M44 1356
3
M44 1336

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-39
7.Note position and remove pump locating dowel.
8.Remove and discard 'O' ring from pump
housing.
9.Remove 6 bolts securing converter housing to
intermediate plate, and release intermediate
plate from converter housing.Refit
1.Clean intermediate plate and mating faces with
a lint free cloth.
2.Position intermediate plate to converter
housing, fit bolts and tighten evenly to 46 Nm
(34 lbf.ft)
3.Fit new sealing washers to M14 Allen plugs, fit
plugs and tighten to 40 Nm (30 lbf.ft).
4.Fit new sealing washers to M20 plugs, fit plugs
and tighten to 50 Nm (37 lbf.ft).
5.Fit oil cooler adaptors and tighten to 42 Nm (30
lbf.ft)
6.Clean pump housing and mating face on
intermediate plate with lint free cloth.
7.Lubricate new 'O' ring with transmission fluid
and fit to pump housing.
8.Position pump locating dowel into intermediate
plate.
9.Align pump to dowel and position in
intermediate plate.
10.Fit bolts and tighten in a diagonal sequence to
10 Nm (7 lbf.ft)
11.Position LRT-44-003/1 into pump and check
that the pump rotors turn freely.
12.Fit intermediate plate gasket.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Gasket - intermediate plate.
M44 1341
M44 1357
M44 1342
LRT-44-003/1

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-46 REPAIRS
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.Fit intercooler.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Intercooler.
6.Check and if necessary top up gearbox fluid.
Cooler - fluid - V8
$% 44.24.10
Remove
1. If fitted: Remove engine oil cooler.

+ ENGINE - V8, REPAIRS, Cooler -
engine oil.
2.Disconnect fluid temperature sensor multiplug.
3.Position absorbent cloth under each gearbox
cooler hose connection to collect spillage.
4.Push against coupling release ring and
disconnect both fluid hoses from cooler.
CAUTION: Always fit plugs to open
connections to prevent contamination.
5.Remove screw and release cooler from
radiator.
6.Carefully move radiator towards engine and
remove cooler.

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.

REAR AXLE
51-2 DESCRIPTION AND OPERATION
Description
General
The rear axle consists of an axle casing with a differential unit attached to the right of the vehicle centre line. A wheel
hub is installed in each end of the axle casing and connected to the differential unit by a drive shaft.
Axle casing
The axle casing is of welded construction, with brackets on the casing exterior for attachment to the rear suspension.
A differential cover on the rear of the axle casing contains an oil level plug for checking and replenishment of the
differential unit lubricating oil. A magnetic drain plug is installed on the underside of the axle casing.
The interior of the axle casing is ventilated through a breather tube inserted in a red plastic sleeve in the top of the
casing. The open end of the breather tube is located between the chassis and the left rear wheelarch.
Differential unit
The differential unit is of the spiral bevel type, lubricated by splash oil. The unit consists of a differential carrier
attached to a pinion housing. In the pinion housing, the pinion is splined to a pinion flange which is secured with a bolt
and washer. An oil seal prevents leakage past the pinion flange.
Centralising peg
The centralising peg is a press fit in the centre of the pinion flange and provides a positive location for the rear
propellor shaft to ensure it is centralised with the flange.

REAR AXLE
51-8 REPAIRS
Refit
1.Clean pinion oil seal recess and pinion flange.
2.Lubricate oil seal lip with clean differential oil.

+ CAPACITIES, FLUIDS AND
LUBRICANTS, Lubrication.
3.Using tool LRT-51-010, fit pinion oil seal.
4.Fit pinion flange and securing bolt and washer.
Using tool LRT-51-003 to restrain pinion
flange, tighten pinion flange securing bolt to
100 Nm (74 lbf.ft).
5.Using a tubular drift, fit centralising peg to
pinion flange. Ensure that large diameter part of
centralising peg is below pinion flange
mounting surface.
6.Position propeller shaft and align reference
marks.
7.Fit nuts and bolts securing flexible coupling to
pinion flange and tighten to 76 Nm (55 lbf.ft).
8.Remove stand(s) and lower vehicle.
9.Check differential oil level.

+ MAINTENANCE, PROCEDURES,
Front and rear axle.
M51 0047A
LRT-51-003

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.