Defender 90 NAS. Manual — part 40
44
AUTOMATIC GEARBOX
10
FAULT DIAGNOSIS
FAULT SYMPTOMS
SYMPTOM 1 - Intermittent drive and high pitched
noise
FAULT - Low fluid level or restricted filter
SYMPTOM 2 - No drive in reverse
Select ’D’
•
No drive
FAULT - Continue with Symptom 3
•
Drives forward
FAULT - Reverse gear interlock valve seized
Select ’1’
•
No engine braking
FAULT - Clutch brake 3
SYMPTOM 3 - No drive from rest with ’D’ selected
Select ’1’
•
Vehicle drives
FAULT - No 2 freewheel
•
No drive
Carry out main line pressure check
•
Normal pressure
FAULT - Clutch A
•
No pressure
FAULT - Blocked filter or pump failure
•
Low pressure
FAULT - Restricted filter or sticking primary
regulator
SYMPTOM 4 - Slip in all forward gears
Carry out main line pressure check
•
No pressure
FAULT - Blocked filter or pump failure
•
Low pressure
FAULT - Restricted filter or sticking primary
regulator
•
Normal pressure
FAULT - Clutch ’A’
SYMPTOM 5 - Harsh engagement ’N’ to ’D’
Check engine idle speed
Carry out main line pressure check
•
High pressure
FAULT - Primary regulator stuck
•
Normal pressure
FAULT - Clutch ’A’ or damper for clutch’A’
SYMPTOM 6 - Fierce shift or flare 1st to 2nd shift
Check engine idle speed
Carry out mainline pressure check
•
High pressure
FAULT - Continue with symptom 5
•
Normal pressure
FAULT - Modulator valve or dampers for clutch
brake CB1 and/or clutch brake CB2
FAULT - Clutch brake CB1 and/or clutch brake
CB2
SYMPTOM 7 - Fierce shift or flare 2nd to 3rd
Carry out mainline pressure check
•
High pressure
FAULT - Continue with symptom 5
•
Normal pressure
FAULT - Modulator valve or clutch ’B’ damper
FAULT - Clutch ’B’
SYMPTOM 8 - No 3rd gear
FAULT - 2-3 shift valve
FAULT - Clutch ’B’
SYMPTOM 9 - No 4th gear ’D’ selected
FAULT - 4th to 3rd downshift valve stuck or 3rd
to 4th upshift valve stuck
FAULT - Clutch brake 4
AUTOMATIC GEARBOX
11
FAULT DIAGNOSIS
SYMPTOM 10 - None or harsh engagement of
direct drive clutch
NOTE: The direct drive clutch will only
engage if 4th gear is engaged at 40 to 45
mph.
Carry out road test pressure check with gauge
connected to torque converter.
•
Normal pressure
FAULT - Failed direct drive clutch
•
Pressures correct but remains high
FAULTS POSSIBLE -
Direct drive clutch and torque converter control
valve stuck
Hysteresis valve stuck
Direct drive clutch control valve stuck
SYMPTOM 11 - Direct drive clutch shift point
incorrect or at low speed
NOTE: Direct drive clutch engagement at
low speed will cause vibration in the
torque converter
Carry out mainline and torque converter pressure
check
•
Normal pressure
FAULT - Governor valve sticking
•
Low or incorrect pressure
FAULTS POSSIBLE -
Direct drive clutch and torque converter control
valve sticking.
Hysteresis valve stuck.
Direct drive clutch control valve stuck.
SYMPTOM 12 - Drives in ’D’ but immediately
upshifts to 3rd
FAULT - 2nd to 3rd shift valve stuck.
SYMPTOM 13 - With ’D’ selected vehicle starts in
2nd
FAULTS POSSIBLE -
1st and 2nd shift valve stuck.
Governor sleeve sticking.
SYMPTOM 14 - With ’D’ selected vehicle starts in
3rd
FAULTS POSSIBLE -
1st to 2nd and 2nd to 3rd shift valves stuck.
Governor sleeve sticking.
SYMPTOM 15 - No kickdown 4th to 3rd
FAULT - 4th to 3rd kickdown valve stuck.
SYMPTOM 16 - Upshifts/downshifts and kickdown
shifts at incorrect road speeds
Check throttle kickdown cable adjustment
Carry out main line pressure check
•
Normal pressure
FAULT - Governor valve sticking
•
Incorrect pressure
FAULTS POSSIBLE -
Incorrect throttle valve adjustment
Primary regulator sticking
SYMPTOM 17 - No upshifts at light throttle
FAULTS POSSIBLE
Governor valve sticking
Shift valves sticking
SYMPTOM 18 - No engine braking ’3’ selected 3rd
gear
FAULT - Clutch ’C’
SYMPTOM 19 - Delayed or no downshift occurs
when making a manual selection from ’3’ to ’2’
FAULTS POSSIBLE -
2nd and 3rd upshift valve sticking.
Governor valve sticking.
’2’ Position interlock valve sticking.
SYMPTOM 20 - At speeds below 28 mph when
making a manual selection from ’2’ to ’1’,
downshift is delayed or does not occur
FAULTS POSSIBLE -
Governor sticking.
1st to 2nd shift valve sticking.
’1’ Position interlock valve sticking.
SYMPTOM 21 - ’1’ Selected 1st gear no engine
braking
FAULT - Clutch brake 3
SYMPTOM 22 - ’2’ Selected 2nd gear no engine
braking
FAULT - Clutch brake 1
SYMPTOM 23 - Vehicle drives forward in ’N’
FAULT - Clutch ’A’ stuck
AUTOMATIC GEARBOX
1
ADJUSTMENT
KICKDOWN CABLE ADJUSTMENT
Service repair no - 44.30.02
1. Release and remove kick-down cable clevis pin.
2. Loosen locknut and release kickdown cable from
abutment bracket.
3. Release outer cable sleeve from clip on rear of
LH cylinder head.
4. Holding cable as straight as possible, extend
inner cable to first detent.
5. With inner cable extended, check dimension A
between end of threads and crimped sleeve.
Dimension A = 42 mm
±
3 mm, 1.65
±
0.10 in.
6. Connect cable to abutment bracket and fit
locknut.
7. Secure outer cable sleeve to clip on rear of LH
cylinder head.
8. Connect kick-down cable to throttle lever and
secure with clevis pin.
9. Adjust outer cable until crimped sleeve is
dimension B from end of outer cable.
Dimension B = 1 mm, 0.04 in.
10. Tighten locknut.
AUTOMATIC GEARBOX
1
REPAIR
KICKDOWN CABLE
Service repair no - 44.15.01
Remove
1. Site vehicle on a four post ramp [hoist].
2. Select neutral ’N’.
3. Disconnect battery negative lead.
4. Remove clevis pin and release kickdown cable
at throttle linkage.
5. Release outer cable locknut.
6. Disconnect cable from abutmet bracket.
7. Release cable from retaining clip at bracket
attached to cylinder head.
8. Feed cable through to underside of vehicle.
9. Raise vehicle on ramp [hoist].
10. Remove gearbox fluid pan
See Fluid pan
gasket and screen.
11. Remove 13 bolts securing control unit assembly
to gearbox.
12. Rotate accelerator cam and release nipple of
kickdown inner cable from cam.
13. Using special tool LRT-44-004, compress cable
tangs and remove cable from gearbox.
14. If cable is to be refitted, remove ’O’ ring seal and
clean cable assembly.
Refit
15. Fit NEW ’O’ ring seal to cable and lubricate seal.
16. Fit cable to gearbox casing ensuring it is
correctly seated.
17. Spring load cam by turning once and fit inner
cable nipple into cam seat.
NOTE: When a new cable is fitted, to help
locate nipple to cam, introduce a curve
into the cable. DO NOT bend or kink cable.
18. Ensuring cable nipple remains engaged, feed
free end of cable assembly into engine
compartment.
19. Locate control unit assembly to gearbox and
loosely fit 13 bolts. Ensure selector shaft locates
into gear shift fork.
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