Discovery 2. Manual — part 575

AUTOMATIC GEARBOX - ZF4HP22 - 24

REPAIRS

44-39

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.

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 1341

M44 1357

M44 1342

LRT-44-003/1

AUTOMATIC GEARBOX - ZF4HP22 - 24

44-40

REPAIRS

Pump - fluid

$% 44.32.01

Remove

1. Remove intermediate plate gasket.

+

AUTOMATIC GEARBOX - ZF4HP22

- 24, REPAIRS, Gasket - intermediate plate.

2. Remove 8 bolts securing fluid pump to

intermediate plate and carefully remove pump
from intermediate plate.

3. Note position and remove pump locating dowel.
4. Remove and discard 'O' ring from pump

housing.

Refit

1. Clean pump housing and mating face on

intermediate plate with lint free cloth.

2. Lubricate new 'O' ring with transmission fluid

and fit to pump housing.

3. Position pump locating dowel into intermediate

plate.

4. Align fluid pump to dowel and position in

intermediate plate.

5. Fit bolts and tighten in a diagonal sequence to

10 Nm (7 lbf.ft)

6. Position LRT-44-003/1 into pump and check

that the pump rotors turn freely.

7. Fit intermediate plate gasket.

+

AUTOMATIC GEARBOX - ZF4HP22

- 24, REPAIRS, Gasket - intermediate plate.

M44 1336

M44 1341

M44 1342

LRT-44-003/1

AUTOMATIC GEARBOX - ZF4HP22 - 24

REPAIRS

44-41

Seal - rear extension housing

$% 44.20.18

Remove

1. Remove transfer box

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TRANSFER BOX - LT230SE,

REPAIRS, Transfer box - Diesel.

+

TRANSFER BOX - LT230SE,

REPAIRS, Transfer box - V8.

2. Drain automatic gearbox oil.

+

MAINTENANCE, PROCEDURES,

Automatic gearbox.

3. Remove rear extension housing oil seal from

gearbox.

Refit

1. Clean oil seal recess in gearbox and running

surface on input shaft.

2. Lubricate oil seal running surface with

transmission oil.

3. Using tool LRT-44-001 fit oil seal to extension

housing.

4. Fit transfer box

+

TRANSFER BOX - LT230SE,

REPAIRS, Transfer box - Diesel.

+

TRANSFER BOX - LT230SE,

REPAIRS, Transfer box - V8.

5. Fill automatic gearbox with oil.

+

MAINTENANCE, PROCEDURES,

Automatic gearbox.

AUTOMATIC GEARBOX - ZF4HP22 - 24

44-42

REPAIRS

Gasket - rear extension housing.

$% 44.20.19

Remove

1. Drain automatic gearbox oil.

+

MAINTENANCE, PROCEDURES,

Automatic gearbox.

2. Remove transfer gearbox.

+

TRANSFER BOX - LT230SE,

REPAIRS, Transfer box - Diesel.

+

TRANSFER BOX - LT230SE,

REPAIRS, Transfer box - V8.

3. Remove 9 bolts securing rear extension

housing to gearbox case and remove housing.

4. Remove and discard gasket.

Reassembly

1. Clean rear extension and mating face.
2. Position new gasket to gearbox case.
3. Position rear extension housing and tighten

bolts to 25 Nm (18 lbf.ft).

4. Fit transfer gearbox.

+

TRANSFER BOX - LT230SE,

REPAIRS, Transfer box - Diesel.

+

TRANSFER BOX - LT230SE,

REPAIRS, Transfer box - V8.

5. Fill automatic gearbox with oil.

+

MAINTENANCE, PROCEDURES,

Automatic gearbox.