Discovery 2. Manual — part 573
AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS
44-31
11. Remove rear propeller shaft
12. Remove plug from torque converter housing to
access torque converter bolts.
13. Remove and discard 4 bolts securing torque
converter to drive plate.
14. Remove hand brake drum retaining screw and
remove brake drum.
15. Remove 4 bolts from hand brake back plate,
release back plate and tie aside.
16. Remove retaining clip securing high/low ratio
selector cable to transfer gearbox lever,
remove 'C' clip and remove outer cable from
gearbox.
17. Disconnect 2 Lucars from differential lock
switch and multiplugs from high/low ratio switch
and neutral sensor.
18. Remove cable tie and multiplug from bracket
on transfer gearbox.
19. Release transfer and automatic gearbox
breather pipes from clip at rear of cylinder
block.
AUTOMATIC GEARBOX - ZF4HP22 - 24
44-32
REPAIRS
20. Position gearbox support jack and secure tool
LRT-99-008A to support plate on jack.
21. Position a second support jack under engine
using a block between engine sump and jack to
prevent damage to sump.
22. Remove 4 bolts and nut, remove engine LH
rear mounting.
23. Remove 4 bolts and nut, remove engine RH
rear mounting.
24. Remove bolt securing gearbox oil cooler pipe
clips to engine.
25. Remove bolt and 2 nuts securing clamps to oil
cooler pipes and remove clamps.
26. Loosen gearbox oil cooler pipe unions, release
pipes from gearbox and discard 'O' rings.
CAUTION: Always fit plugs to open
connections to prevent contamination.
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.
AUTOMATIC GEARBOX - ZF4HP22 - 24
44-34
REPAIRS
24. Fit front propeller shaft.
25. Fill transfer gearbox with oil.
26. Fill automatic gearbox with oil.
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.
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.
- 24, ADJUSTMENTS, Cable - selector.
Torque converter and oil seal
$% 44.17.07
Remove
1. Remove automatic gearbox.
l
ZF4HP22 - 24, REPAIRS, Gearbox -
convertor and transfer gearbox - Diesel.
l
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.
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