Discovery 2. Manual — part 152

AUTOMATIC GEARBOX - ZF4HP22 - 24

REPAIRS

44-39

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.

Gasket - intermediate plate

$% 44.20.11

Remove

1. Remove torque converter oil seal.

+

AUTOMATIC GEARBOX - ZF4HP22

- 24, REPAIRS, Torque converter and oil
seal.

2. Remove 12 bolts and plain washers securing

converter housing and intermediate plate to
gearbox casing. Note the position of the 4 bolts
that have sealant applied to the bolt threads.

3. Hold input shaft in position and carefully lift off

converter housing and intermediate plate as an
assembly. Note the position of the Torrington
race on the forward clutch hub, and the thrust
washer which will stay attached to the
intermediate plate by fluid adhesion.

4. Remove and discard intermediate plate gasket.
5. Remove thrust washer from intermediate plate.

M44 1344

M44 1345

AUTOMATIC GEARBOX - ZF4HP22 - 24

44-40

REPAIRS

Refit

1. Clean intermediate plate and mating face on

gearbox casing.

2. Apply Petroleum Jelly to new gasket and

position on gearbox casing.

3. Apply Petroleum Jelly to thrust washer and

Torrington race.

4. Correctly position Torrington race and thrust

washer to forward clutch hub.

5. Position converter housing and intermediate

plate assembly to gearbox casing.

6. Clean bolts and plain washers and old sealant

from 4 bolt threads.

7. Apply sealant, Part No. STC 50553 to 4 longer

bolt threads and fit bolts in position shown.

8. Fit remaining bolts and tighten progressively in

a diagonal sequence to 46 Nm (34 lbf.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 (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.

M44 1344

M44 1358

LRT-44-003/1

AUTOMATIC GEARBOX - ZF4HP22 - 24

REPAIRS

44-41

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.

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.

2

4

4

3

M44 1356

3

M44 1336

M44 1341

M44 1357

AUTOMATIC GEARBOX - ZF4HP22 - 24

44-42

REPAIRS

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 1342

LRT-44-003/1