Range Rover. Manual — part 164
ZF AUTO
25
REPAIR
Refit
7. Clean intermediate plate and mating face on
gearbox casing.
8. Apply Petroleum Jelly to new gasket and
position on gearbox casing.
9. Apply Petroleum Jelly to thrust washer and
torrington race.
10. Correctly position torrington race and thrust
washer to forward clutch hub.
11. Position converter housing and intermediate
plate assembly to gearbox casing.
12. Clean bolts and plain washers and old sealant
from 4 bolt threads.
13. Apply High Formular Hylomar sealant to 4 longer
bolt threads and fit bolts in position shown.
14. Fit remaining bolts and tighten progressively in a
diagonal sequence to
45 Nm (33 lbf. ft).
15. Place LRT-44-003/1 into pump housing, tighten
screws to secure LRT-44-003/1 to input shaft.
16. Clamp a suitable steel base to converter housing
flange.
17. Mount DTI gauge and position gauge probe onto
LRT-44-003/1 and zero gauge.
18. Check that the axial end-float is between 0.2 to
0.4 mm. 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.
19. Remove DTI gauge and base plate.
20. Fit torque converter oil seal.
See this section.
44
AUTOMATIC GEARBOX
NEW RANGE ROVER
26
REPAIR
INTERMEDIATE PLATE
Service repair no - 44.17.20
Remove
1. Remove intermediate plate gasket.
See this
section.
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.
ZF AUTO
27
REPAIR
Refit
10. Clean intermediate plate and mating faces with a
lint free cloth.
11. Position intermediate plate to converter housing,
fit bolts and tighten evenly to
50 Nm (37 lbf.ft)
12. Fit new sealing washers to M14 allen plugs, fit
plugs and tighten to
40 Nm (30lbf. ft).
13. Fit new sealing washers to M20 plugs, fit plugs
and tighten to
50 Nm (37lbf. ft).
14. Fit oil cooler adaptors and tighten to
42 Nm
(30lbf.ft).
15. Clean pump housing and mating face on
intermediate plate with lint free cloth.
16. Lubricate new ’O’ ring with transmission fluid and
fit to pump housing.
17. Position pump locating dowel into intermediate
plate.
18. Align pump to dowel and position in intermediate
plate.
19. Fit bolts and tighten in a diagonal sequence to
10 Nm (7lbf.ft).
20. Position LRT-44-003/1 into pump and check that
the pump rotors turn freely.
21. Fit intermediate plate gasket.
See this section.
PUMP - FLUID
Service repair no - 44.32.01
Remove
1. Remove intermediate plate gasket.
See this
section.
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.
44
AUTOMATIC GEARBOX
NEW RANGE ROVER
28
REPAIR
Refit
5. Clean pump housing and mating face on
intermediate plate with lint free cloth.
6. Lubricate new ’O’ ring with transmission fluid and
fit to pump housing.
7. Position pump locating dowel into intermediate
plate.
8. Align fluid pump to dowel and position in
intermediate plate.
9. Fit bolts and tighten in a diagonal sequence to
10 Nm (7lbf.ft).
10. Position LRT-44-003/1 into pump and check that
the pump rotors turn freely.
11. Fit intermediate plate gasket.
See this section.
OUTPUT SHAFT SEAL
Service repair no - 44.20.18
Remove
1. Disconnect battery negative lead.
2. Remove transfer box.
See TRANSFER BOX,
Repair.
3. Drain fluid from gearbox.
See SECTION 10,
Maintenance.
4. Remove seal from gearbox casing using a
suitable lever.
CAUTION: Ensure location does not
become damaged as seal is levered from
casing.
Refit
5. Clean seal location and running surface on
transfer gearbox input shaft.
6. Lubricate seal lip with clean transmission fluid.
7. Fit seal to gearbox casing using LRT-44-001
8. Fit transfer box.
See TRANSFER BOX, Repair.
9. Reconnect battery negative lead.
10. Replenish transmission fluids.
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information.
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