Discovery 2. Manual — part 149

AUTOMATIC GEARBOX - ZF4HP22 - 24

REPAIRS

44-27

Gearbox - convertor and transfer
gearbox - Diesel

$% 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 starter motor.

+

CHARGING AND STARTING,

REPAIRS, Starter motor - diesel.

5. Remove 2 upper bolts securing gearbox

housing to engine.

6. Remove bolt securing closing plate to gearbox

housing.

7. Remove exhaust front pipe.

+

MANIFOLDS AND EXHAUST

SYSTEMS - Td5, REPAIRS, Pipe - front.

8. Remove 3 nuts securing intermediate silencer

to tail pipe.

9. Release and remove silencer from rubber

mountings.

10. Drain automatic gearbox oil.

+

MAINTENANCE, PROCEDURES,

Automatic gearbox.

11. Drain transfer gearbox oil.

+

MAINTENANCE, PROCEDURES,

Transfer box.

12. Remove front propeller shaft.

+

PROPELLER SHAFTS, REPAIRS,

Propeller shaft - front.

13. Remove rear propeller shaft.

+

PROPELLER SHAFTS, REPAIRS,

Propeller shaft - rear.

14. Remove and discard 3 bolts securing torque

converter to drive plate.

AUTOMATIC GEARBOX - ZF4HP22 - 24

44-28

REPAIRS

15. Remove handbrake drum retaining screw and

remove brake drum.

16. Remove 4 bolts from handbrake back plate,

release back plate and tie aside.

17. Models fitted with high/low shift interlock

solenoid: Release interlock solenoid multiplug
and disconnect multiplug from main harness.

18. Models fitted with high/low shift interlock

solenoid: Remove sleeve retaining rings and
remove sleeve from high/low selector cable.

19. If fitted Remove and discard clevis pin

securing differential lock selector cable to
transfer gearbox.

20. If fitted Loosen locknuts securing differential

lock selector cable to differential lock selector
cable abutment bracket.

21. If fitted Release and remove differential lock

selector cable from differential lock selector
cable abutment bracket.

22. Remove clevis pin securing high/low ratio

selector cable to selector lever, remove 'C' clip
and remove outer cable from abutment
bracket.

23. Up to 03 Model Year - If fitted: Disconnect

from differential lock warning lamp switch and
multiplugs from high/low ratio switch and
neutral sensor.

AUTOMATIC GEARBOX - ZF4HP22 - 24

REPAIRS

44-29

24. 03 Model Year onwards - If fitted: Release

and disconnect both differential lock warning
lamp switch multiplugs from main harness.

25. Remove cable tie and multiplug from bracket

on transfer box.

26. Release transfer and automatic gearbox

breather pipes from clip at rear of cylinder
block.

27. Position gearbox support jack and secure tool

LRT-99-008A to support plate on jack.

28. Position a second support jack under engine

using a block between engine sump and jack
to prevent damage to sump.

29. Remove 4 bolts and nut, remove engine LH

rear mounting.

30. Remove 4 bolts and nut, remove engine RH

rear mounting.

31. Remove 2 bolts securing gearbox oil cooler

pipe clips to engine sump and alternator
mounting bracket.

AUTOMATIC GEARBOX - ZF4HP22 - 24

44-30

REPAIRS

32. Remove bolt and 2 nuts securing clamps to oil

cooler pipes and remove clamps.

33. Loosen gearbox oil cooler pipe unions, release

pipes from gearbox and discard 'O' rings.

CAUTION: Always fit plugs to open
connections to prevent contamination.

34. Remove 'C' clip securing selector cable to

gearbox bracket.

35. Remove nut securing selector lever to inhibitor

switch and release lever.

36. Disconnect multiplug from inhibitor switch.
37. Loosen gearbox multi plug locking ring and

disconnect plug.

38. Remove 6 remaining gearbox housing bolts.
39. With assistance remove automatic gearbox

from engine.