Range Rover Classic. Manual — part 77

44

AUTOMATIC GEARBOX

10

REPAIR

OIL INLET SEALING RINGS

Service repair no - 44.20.13

1. Site vehicle on ramp. Disconnect battery

negative lead.

2. Drain gearbox oil into a container.

3. Discard sump plug seal.
4. Remove oil level tube from sump.
5. Remove six retaining plates and bolts.
6. Remove sump, discard gasket.
7. Loosen three bolts and remove oil screen.
8. Loosen remaining thirteen bolts retaining control

unit.

9. Clean surfaces using a lint-free rag. Ensure no

damage has occurred to mounting face of case.

10. Remove eight circlips and springs from gearbox.
11. Using LST 113 remove eight oil seals.
12. Clean orifices, check for damage.

NOTE: If damage has occurred replace
box.

See ZF Auto with Borg Warner

Transfer Gearbox

13. Using LST 113 fit new seals.
14. Fit eight compression springs, four short ones at

front and four long ones at rear.

15. Fit eight circlips to retain compression springs.
16. Fit control unit locating selector shaft into gear

shift fork. Fit thirteen bolts loosely.

17. Place setting gauge LST 109 in position. Press

control unit against tool, tighten thirteen bolts to
8Nm.

ZF

11

REPAIR

18. Remove setting gauge. Fit oil screen, tighten

fixings to

8 Nm.

19. Refit oil pan with new gasket.
20. Secure with six retaining plates and bolt.

Tighten to

8 Nm.

21. Reconnect oil level tube. Tighten to

70 Nm.

22. Fit sump plug with new seal. Tighten to

10 Nm.

23. Reconnect battery negative lead.
24. Add correct quantity and grade of oil to gearbox.

See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids

25. Ensure vehicle is on level ground with park

brake applied. Check oil level with engine at idle,
neutral selected, after selecting each gear.

MANUAL VALVE OPERATING MECHANISM

Service repair no - 44.40.01

1. Site vehicle on ramp. Disconnect battery

negative lead.

2. Drain gearbox oil into a container. Discard sump

plug seal.

3. Remove oil level tube from sump.
4. Remove six retaining plates and bolts.
5. Remove sump, discard gasket.
6. Loosen three bolts and remove oil screen.
7. Loosen remaining thirteen bolts retaining control

unit.

44

AUTOMATIC GEARBOX

12

REPAIR

8. Locate selector cam, remove kickdown cable

nipple from its seat.

9. Remove gear change lever.

10. Drift out roll pin from selector shaft, discard pin.
11. Remove selector shaft from box, note position of

detent plate for reassembly.

12. Remove connecting rod with detent plate,

accelerator cam, and spring. Remove and
discard oil seal.

13. Check all parts for wear or damage, replace as

necessary.

14. Using LST114, fit oil seal use petroleum jelly to

aid assembly.

15. Fit connecting rod to detent plate, locate in box

by pushing selector shaft through from outside of
casing.

16. Fit accelerator cam with spring.
17. Fit assembly into box and secure by pushing

selector shaft through.

18. Align hole in selector shaft with hole in detent

plate. Secure with a new roll pin.

19. Spring load cam by turning once. Fit kickdown

cable nipple into cam seat.

20. Fit control unit ensuring selector shaft locates

into gear shift fork. Fit thirteen bolts loosely.

21. Position setting gauge LST 109. Press control

unit against tool. Tighten thirteen bolts to

8 Nm.

22. Remove setting gauge, fit oil screen, tighten

fixings to

8 Nm.

23. Refit oil pan with new gasket.
24. Secure with six retaining plates and bolt.

Tighten to

8 Nm.

25. Reconnect oil level tube. Tighten to

70 Nm.

26. Fit sump plug with new seal. Tighten to

10 Nm.

27. Reconnect battery negative lead.
28. Add correct quantity and grade of oil to gearbox.

See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids

29. Ensure vehicle is on level ground with park

brake applied. Check oil level with engine at idle,
neutral selected, after selecting each gear.

ZF

13

REPAIR

GOVERNOR HOUSING

Service repair no - 44.22.01

Remove

1. Remove transfer box.

See TRANSFER

GEARBOX, Repair, Borg Warner Transfer
Gearbox

2. Remove transfer gear selector housing.
3. Loosen nine bolts holding extension housing.
4. Remove extension housing ensuring that seal is

not damaged, discard gasket.

5. Remove extension shaft and retaining bolt with

’O’ ring. If Tdi vehicle, remove spacer.

6. Remove governor assembly with parking wheel.
7. Remove two screws holding governor housing.
8. Remove governor housing complete and

discard.

9. Inspect governor hub and parking wheel for

damage.

Refit

10. Fit new governor housing complete to governor

hub and parking wheel. Tighten to

10 Nm.

11. Push governor assembly with parking wheel

onto output shaft until fully seated.

NOTE: Apply petroleum jelly to ’O’ ring.
Ensure seal rings are snapped together
and seated.

12. Fit extension shaft, with spacer if Tdi, apply

Loctite 270 to retaining bolt. Using a new ’O’
ring. Tighten to

42 Nm.

13. Fit new gasket to rear of gearbox. Fit extension

housing, avoid damage to seal.

14. Tighten nine extension housing nine bolts to

23

Nm.

15. Fit transfer gear selector housing.
16. Tighten three bolts to

25Nm.

17. Refit transfer box.