Discovery 2. Manual — part 572
AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS
44-27
11. Drain transfer gearbox oil.
12. Remove front propeller shaft
13. Remove rear propeller shaft
14. Remove and discard 3 bolts securing torque
converter to drive plate.
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. Remove clip securing high/low ratio selector
cable to transfer gearbox lever, remove 'C' clip
and remove outer cable from gearbox.
18. Disconnect 2 Lucars from differential lock
switch and multiplugs from high/low ratio switch
and neutral sensor.
19. Remove cable tie and multi plug from bracket
to transfer box.
AUTOMATIC GEARBOX - ZF4HP22 - 24
44-28
REPAIRS
20. Release transfer and automatic gearbox
breather pipes from clip at rear of cylinder
block.
21. Position gearbox support jack and secure tool
LRT-99-008A to support plate on jack.
22. Position a second support jack under engine
using a block between engine sump and jack
to prevent damage to sump.
23. Remove 4 bolts and nut, remove engine LH
rear mounting.
24. Remove 4 bolts and nut, remove engine RH
rear mounting.
25. Remove 2 bolts securing gearbox oil cooler
pipe clips to engine sump and alternator
mounting bracket.
26. Remove bolt and 2 nuts securing clamps to oil
cooler pipes and remove clamps.
AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS
44-29
27. Loosen gearbox oil cooler pipe unions, release
pipes from gearbox and discard 'O' rings.
CAUTION: Always fit plugs to open
connections to prevent contamination.
28. Remove 'C' clip securing selector cable to
gearbox bracket.
29. Remove nut securing selector lever to inhibitor
switch and release lever.
30. Disconnect multiplug from inhibitor switch.
31. Loosen gearbox multi plug locking ring and
disconnect plug.
32. Remove 6 remaining gearbox housing bolts.
33. With assistance remove automatic gearbox
from engine.
34. 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. Position selector lever to inhibitor switch and
tighten nut to 25 Nm (18 lbf.ft).
8. Position selector cable to gearbox and secure
with 'C' clip.
9. Clean oil pipe unions and fit new 'O' rings.
10. Position and tighten pipe unions to gearbox.
11. Position and tighten oil cooler pipe clamps.
12. Position and tighten oil cooler pipe clips to
engine sump and alternator bracket.
13. Position engine RH and LH rear mountings
and tighten bolts to 85 Nm (63 lbf.ft) and nuts to
85 Nm (63 lbf.ft).
AUTOMATIC GEARBOX - ZF4HP22 - 24
44-30
REPAIRS
14. Secure gearbox breather pipes to bulkhead
clip.
15. Connect multiplugs to high/low ratio switch and
neutral sensor. Connect Lucars to differential
lock switch.
16. Position cable tie and multi plug to transfer box
bracket.
17. Connect high/low ratio cable to transfer box
and secure with retaining clips.
18. Position hand brake back plate and tighten
bolts to 75 Nm (55 lbf.ft).
19. Fit hand brake drum and tighten screw.
20. Remove bolts securing tool LRT-99-008A to
gearbox.
21. Rotate engine to align torque converter, fit new
bolts and tighten to 50 Nm (37 lbf.ft).
22. Fit rear propeller shaft.
23. Fit front propeller shaft.
24. Fill transfer gearbox with oil.
25. Fill automatic gearbox with oil.
26. Position intermediate silencer and secure to
mounting rubbers.
27. Clean silencer and tail pipe mating faces.
28. Position new gasket to tail pipe and tighten
nuts to 25 Nm (18 lbf.ft).
29. Fit exhaust front pipe.
SYSTEMS - Td5, REPAIRS, Pipe - front.
30. Fit bolt securing closing plate to gearbox
housing and tighten to 7 Nm (5.2 lbf.ft).
31. Fit upper bolts securing gearbox housing to
engine and tighten to 50 Nm (37 lbf.ft).
32. Fit starter motor.
REPAIRS, Starter motor - diesel.
33. Tighten remaining gearbox housing to engine
bolts to 50 Nm (37 lbf.ft).
34. Connect battery earth lead.
35. Fit battery cover and secure with fixings.
36. Check and adjust selector cable.
- 24, ADJUSTMENTS, Cable - selector.
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
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