Range Rover. Manual — part 162
ZF AUTO
17
REPAIR
AUTOMATIC GEARBOX - FROM 99MY
Service repair no - 44.20.04.99
Remove
1. Position vehicle on a four post lift.
2. Release fixings from battery cover and remove
cover.
3. Disconnect battery earth lead.
4. Petrol models: Release clips securing cooling
fan cowl and remove cowl.
5. Petrol models: Remove 3 bolts securing engine
RH lifting eye to cylinder head and position earth
strap and lifting eye aside.
6. Diesel Models: Remove starter motor.
See
ELECTRICAL, Repair.
7. Remove window switch pack.
See
ELECTRICAL, Repair.
8. With the handbrake released, remove clip and
clevis pin securing handbrake cable to
handbrake.
9. Raise vehicle and release handbrake cable and
grommet from tunnel.
10. Drain gearbox
See this section. See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information.
11. Drain transfer gearbox fluid.
See SECTION 10,
Maintenance. See LUBRICANTS, FLUIDS
AND CAPACITIES, Information.
12. Petrol models: Remove exhaust front pipe.
See MANIFOLD AND EXHAUST SYSTEM,
Repair.
13. Diesel models: Remove chassis crossmember.
See CHASSIS AND BODY, Repair.
44
AUTOMATIC GEARBOX
NEW RANGE ROVER
18
REPAIR
14. Remove 4 bolts securing transmission mounting
assembly and remove assembly.
15. Fit LRT-99-007, to transmission jack and secure
to transmission mounting bracket location holes
with bolts.
16. Remove transmission jack from under brake
drum.
17. Remove 4 bolts securing rear propeller shaft
guard and remove guard.
18. Raise one wheel on each axle to allow rotation
of propeller shafts.
19. Mark transfer box and propeller shaft flanges to
aid re-assembly.
ZF AUTO
19
REPAIR
20. Remove 4 nuts from each propeller shaft flange.
21. Release propeller shafts and tie aside.
22. Lower gearbox for access.
CAUTION: Position jack and wooden block
under sump to support engine.
23. Remove split pin securing gear selector cable
trunnion to gearbox lever and release trunnion.
24. Remove 2 bolts securing gear selector cable
abutment bracket and harness support bracket
to gearbox, and position selector cable and
brackets aside.
25. Disconnect multiplugs from gear selection
position switch and gearbox speed sensor.
26. Disconnect 2 Lucars from transfer box fluid
temperature sensor.
27. Disconnect multiplugs from High/Low motor and
output shaft speed sensor.
28. Release harness from 3 clips.
29. Remove 2 banjo bolts securing breather pipes to
gearbox and transfer box, remove and discard
sealing washers.
CAUTION: Plug the connections.
44
AUTOMATIC GEARBOX
NEW RANGE ROVER
20
REPAIR
30. Remove 2 bolts and release 1 clip securing fuel
and purge pipe retaining brackets to gearbox
and transfer box.
31. Remove bolt from clamp securing gearbox fluid
cooler pipes to engine.
32. Loosen unions and release gearbox oil cooler
pipes, discard ’O’ rings.
CAUTION: Plug the connections.
33. Remove 3 bolts securing converter housing
lower access cover, remove cover and discard
gasket.
34. Remove access plug and mark drive plate and
torque convertor to aid re-assembly.
35. Rotate engine to gain access and remove 4
bolts securing drive plate to convertor.
36. Remove 14 bolts securing gearbox to engine
and collect crash bracket.
37. With assistance remove transmission assembly.
CAUTION: Ensure converter does not
become detached from gearbox.
38. Fit retaining strap to converter and secure with 2
nuts and bolts.
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