Discovery 2. Manual — part 150
AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS
44-31
40. 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 but do not tighten six bolts securing gearbox
housing to engine.
5. Connect multiplug to gearbox and tighten
locking ring.
6. Connect multiplug to inhibitor switch.
7. If fitted: Connect and adjust differential lock
selector cable.
ADJUSTMENTS, Cable - selector -
differential lock - adjust.
8. Position selector lever to inhibitor switch and
tighten nut to 25 Nm (18 lbf.ft).
9. Position selector cable to gearbox and secure
with 'C' clip.
10. Clean oil pipe unions and fit new 'O' rings.
11. Position and tighten pipe unions to gearbox.
12. Position and tighten oil cooler pipe clamps.
13. Position and tighten oil cooler pipe clips to
engine sump and alternator bracket.
14. Position engine RH and LH rear mountings
and tighten bolts to 85 Nm (63 lbf.ft) and nuts to
85 Nm (63 lbf.ft).
15. Secure gearbox breather pipes to bulkhead
clip.
16. Up to 03 Model Year - If fitted: Connect 2
Lucars to differential lock warning lamp switch
and multiplugs to high/low ratio switch and
neutral sensor.
17. 03 Model Year onwards - If fitted: Connect
differential lock warning lamp switch multiplugs
to main harness.
18. Position cable tie and multiplug to transfer box
bracket.
19. Connect high/low ratio selector cable to
selector lever and secure with clevis pin.
20. Position high/low ratio selector cable to
abutment bracket and secure with 'C' clip.
21. Models fitted with high/low shift interlock
solenoid: Position interlock solenoid harness
to high/low shift cable, fit sleeve around cable
and harness.
22. Models fitted with high/low shift interlock
solenoid: Connect solenoid multiplug to main
harness and secure multiplug to bracket.
23. Position handbrake backplate and tighten bolts
to 75 Nm (55 lbf.ft).
24. Fit hand brake drum and tighten screw.
25. Remove bolts securing tool LRT-99-008A to
gearbox.
26. Rotate engine to align torque converter, fit new
bolts and tighten to 50 Nm (37 lbf.ft).
27. Fit rear propeller shaft.
28. Fit front propeller shaft.
29. Fill transfer gearbox with oil.
30. Fill automatic gearbox with oil.
31. Position intermediate silencer and secure to
mounting rubbers.
32. Clean silencer and tail pipe mating faces.
33. Position new gasket to tail pipe and tighten
nuts to 25 Nm (18 lbf.ft).
34. Fit exhaust front pipe.
SYSTEMS - Td5, REPAIRS, Pipe - front.
35. Fit bolt securing closing plate to gearbox
housing and tighten to 7 Nm (5.2 lbf.ft).
36. Fit upper bolts securing gearbox housing to
engine and tighten to 50 Nm (37 lbf.ft).
37. Fit starter motor.
REPAIRS, Starter motor - diesel.
38. Tighten remaining gearbox housing to engine
bolts to 50 Nm (37 lbf.ft).
39. Connect battery earth lead.
40. Fit battery cover and secure with fixings.
41. Check and adjust selector cable.
AUTOMATIC GEARBOX - ZF4HP22 - 24
44-32
REPAIRS
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.
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.
9. Drain transfer gearbox oil.
10. Remove front propeller shaft
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.
AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS
44-33
16. Models fitted with high/low shift interlock
solenoid: Release interlock solenoid multiplug
and disconnect multiplug from main harness.
17. Models fitted with high/low shift interlock
solenoid: Remove sleeve retaining rings and
remove sleeve from high/low selector cable.
18. If fitted Remove and discard clevis pin
securing differential lock selector cable to
transfer gearbox.
19. If fitted Loosen locknuts securing differential
lock selector cable to differential lock selector
cable abutment bracket.
20. If fitted Release and remove differential lock
selector cable from differential lock selector
cable abutment bracket.
21. Remove clevis pin securing high/low ratio
selector cable to selector lever, remove 'C' clip
and remove outer cable from abutment bracket
22. Up to 03 Model Year - If fitted: Disconnect 2
Lucars from differential lock switch and
multiplugs from high/low ratio switch and
neutral sensor.
23. 03 Model Year onwards - If fitted: Release
and disconnect both differential lock warning
lamp switch multiplugs from main harness.
24. Release transfer and automatic gearbox
breather pipes from clip at rear of cylinder
block.
AUTOMATIC GEARBOX - ZF4HP22 - 24
44-34
REPAIRS
25. Position gearbox support jack and secure tool
LRT-99-008A to support plate on jack.
26. Position a second support jack under engine
using a block between engine sump and jack to
prevent damage to sump.
27. Remove 4 bolts and nut, remove engine LH
rear mounting.
28. Remove 4 bolts and nut, remove engine RH
rear mounting.
29. Remove bolt securing gearbox oil cooler pipe
clips to engine.
30. Remove bolt and 2 nuts securing clamps to oil
cooler pipes and remove clamps.
31. Loosen gearbox oil cooler pipe unions, release
pipes from gearbox and discard 'O' rings.
CAUTION: Always fit plugs to open
connections to prevent contamination.
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст