Discovery 2. Manual — part 574

AUTOMATIC GEARBOX - ZF4HP22 - 24

REPAIRS

44-35

Refit

1. Clean oil seal running surfaces.
2. Lubricate oil seal with transmission fluid.

3. Fit new seal into converter housing using tool

LRT-44-001.

4. Fit tool LRT-44-010 to torque converter.
5. Align oil pump drive and fit torque converter to

gearbox.

6. Remove tool LRT-44-010 from torque

converter.

7. Fit torque converter retaining strap.
8. Fit automatic gearbox.

l

+

AUTOMATIC GEARBOX -

ZF4HP22 - 24, REPAIRS, Gearbox -
convertor and transfer gearbox - Diesel.

l

+

AUTOMATIC GEARBOX -

ZF4HP22 - 24, REPAIRS, Gearbox -
convertor and transfer gearbox - V8.

Housing - torque converter

$% 44.17.01

Remove

1. Remove torque converter oil seal.

+

AUTOMATIC GEARBOX - ZF4HP22

- 24, REPAIRS, Torque converter and oil
seal.

2. Remove 18 bolts and plain washers securing

torque converter and intermediate plate to
gearbox casing. Note the position of the 4 bolts
that have sealant applied to the bolt threads
and 6 bolts, (outer ring), which are shorter.

3. Hold input shaft in position and carefully

remove the converter housing and intermediate
plate from gearbox casing.

4. 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.

5. Remove and discard intermediate plate gasket.
6. Remove thrust washer from intermediate plate.
7. Separate converter housing from intermediate

plate.

M44 1343

M44 1345

AUTOMATIC GEARBOX - ZF4HP22 - 24

44-36

REPAIRS

Refit

1. Clean converter housing, intermediate plate

and gearbox casing mating faces.

2. Clean bolts and plain washers and sealant from

4 bolt threads.

3. Apply Petroleum Jelly to new gasket and

position on gearbox casing.

4. Apply Petroleum Jelly to thrust washer and

Torrington race.

5. Correctly position Torrington race and thrust

washer to forward clutch hub.

6. Position intermediate plate and converter

housing to gearbox casing.

7. Apply High Formular Hylomar sealant to 4

longer bolt threads and fit bolts in the positions
shown.

8. Fit remaining bolts and tighten progressively in

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

M44 1343

M44 1358

LRT-44-003/1

AUTOMATIC GEARBOX - ZF4HP22 - 24

REPAIRS

44-37

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.

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 High Formular Hylomar sealant 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 (34lbf. 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.

M44 1344

M44 1345

M44 1344

M44 1358

LRT-44-003/1

AUTOMATIC GEARBOX - ZF4HP22 - 24

44-38

REPAIRS

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.

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.

2

4

4

3

M44 1356

3

M44 1336