Range Rover. Manual — part 161
ZF AUTO
13
REPAIR
12. Remove 4 bolts securing rear propeller shaft
guard. Remove guard.
13. Mark transfer box and propeller shaft flanges to
aid re-assembly.
14. Raise one wheel on each axle to allow rotation
of propeller shafts.
15. Remove 4 bolts from each flange. Disconnect
propeller shafts. Tie aside.
16. Lower gearbox for access.
CAUTION: Place wooden block between
axle case and sump to support engine.
17. Disconnect gear selector cable trunnion from
gearbox lever. Remove 2 bolts securing selector
cable abutment bracket to gearbox. Place
selector cable aside.
18. Disconnect 2 Lucars from transfer box fluid
temperature sensor.
44
AUTOMATIC GEARBOX
NEW RANGE ROVER
14
REPAIR
19. Disconnect multiplugs from High/Low motor and
output shaft speed sensor.
20. Disconnect multiplugs from gear selection
position switch and gearbox speed sensor.
21. Release harness from clips.
22. Remove bolt from clamp securing gearbox
cooler pipes to engine.
23. Disconnect transmission cooler pipes. Remove
’O’ rings and discard. Plug pipes and
connections.
24. Release fluid filler pipe from gearbox. Remove
’O’ ring and discard. Plug pipe and connection.
25. Disconnect breather pipes from gearbox and
transfer box. Plug Pipes and connections.
26. Remove 3 bolts securing converter housing
lower access cover. Remove cover. Collect
gasket.
27. Remove 9 bolts securing converter drive plate
access cover. Remove cover.
28. Mark drive plate and converter to aid
re-assembly.
29. Remove 4 bolts securing drive plate to
converter.
ZF AUTO
15
REPAIR
30. Remove 8 bolts securing converter housing to
engine.
31. Remove transmission assembly.
CAUTION: Ensure converter does not
become detached from gearbox.
32. Fit retaining strap to converter. Secure with 2
nuts and bolts.
Do not carry out further dismantling if
component is removed for access only.
33. Lower transmission assembly from vehicle.
34. Attach lifting eyes to transmission.
35. Attach hoist to lifting eyes. Take weight of
transmission.
36. Remove lift adaptor. Hoist transmission
assembly onto bench.
37. Fit lifting eye to transmission brake drum. Raise
gearbox on end.
CAUTION: Position packers beneath bell
housing extension to provide clearance for
input shaft.
38. Remove 6 bolts securing transfer box to
gearbox. Release from 2 ring dowels. Remove
transfer box.
39. Ensure mating faces are clean.
40. Place gearbox on end. Position transfer box.
41. Engage transfer box to ring dowels. Secure to
gearbox with bolts. Tighten to
45 Nm (33 lbf.ft)
CAUTION: Ensure that gearbox is located
on both dowels, or transmission damage
may occur.
42. Place transmission on side. Fit lifting eyes.
43. Attach transmission to lift adaptor. Secure with
bolts.
44. Detach hoist. Remove lifting eyes.
44
AUTOMATIC GEARBOX
NEW RANGE ROVER
16
REPAIR
Refit
45. Ensure converter spigot and mating faces are
clean.
46. Remove converter retaining strap.
47. Position transmission to engine. Secure with
bolts. Tighten to
45 Nm (33 lbf.ft)
48. Position drive plate to converter. Align marks.
Secure with bolts. Tighten to
50 Nm (37 lbf.ft)
49. Position converter access panels. Use a new
gasket with lower panel. Secure panels with
bolts.
50. Remove plugs from breather pipes and
connections.
51. Using new sealing washers, secure breather
pipes to gearbox and transfer box with banjo
bolts.
52. Fit new seals to fluid filler and cooler pipes.
Connect pipes to transmission. Tighten to
22 Nm (16 lbf.ft)
53. Fit clamp to cooler pipes. Secure to engine with
bolt.
54. Route gearbox harness. Secure with clips.
55. Connect multiplugs to High/Low motor and
output shaft speed sensor.
56. Connect multiplugs to gear selection position
switch and gearbox speed sensor.
57. Connect Lucars to transfer box fluid temperature
sensor.
58. Align harness bracket to gearbox.
59. Position selector cable abutment bracket to
gearbox. Secure with bolts.
60. Raise transmission. Support under brake drum
with transmission jack.
61. Remove transmission lift adaptor. Remove lift.
62. Position transmission mounting assembly.
Secure with bolts. Tighten to
45 Nm (33 lbf.ft)
63. Adjust gear selector cable.
See Adjustment.
64. Raise one wheel on each axle to allow rotation
of propeller shafts.
65. Position shafts to transfer box flanges. Align
marks.
66. Secure shafts with nuts and bolts. Tighten to
48 Nm (35 lbf.ft)
67. Fit propeller shaft guard. Secure with bolts.
68. Guide hand brake cable through grommet in
transmission tunnel.
69. Diesel Vehicles:Fit chassis cross member.
See
CHASSIS AND BODY, Repair.
70. Fit exhaust front pipe.
See MANIFOLD AND
EXHAUST SYSTEM, Repair.
71. Fill transfer box with oil.
See LUBRICANTS,
FLUIDS AND CAPACITIES, Information.
72. Lower Vehicle
73. Connect handbrake cable to lever.
74. Fit window switch pack.
See ELECTRICAL,
Repair.
75. Position gearbox filler tube to engine. Secure
with bolt.
76. Petrol Engines:Position cooling fan cowl.
Secure with clips.
77. Fill gearbox with fluid.
See LUBRICANTS,
FLUIDS AND CAPACITIES, Information.
78. Reconnect battery negative lead.
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