Range Rover Classic. Manual — part 80
44
AUTOMATIC GEARBOX
22
REPAIR
REPLACING INTERMEDIATE PLATE
Service repair no - 44.20.11
1. Remove gearbox and transfer box assembly.
See ZF Auto with Borg Warner Transfer
Gearbox
2. Place gearbox on bench. Remove torque
converter using torque converter handles
18G1501.
3. Remove twelve bolts (inner ring pattern).
4. Remove bell housing and pump assembly from
gearbox case, discard gasket.
5. Remove eight bolts from rear of pump.
6. Screw in two bolts, diagonally opposite each
other, tap pump to free pump assembly from
intermediate plate.
7. Remove ’O’ ring from pump housing and
discard.
8. Place bell housing and intermediate plate
assembly on bench.
ZF
23
REPAIR
9. Remove six bolts and remove bell housing from
intermediate plate assembly.
10. Remove four screw plugs and seal rings from
intermediate plate, discard seal rings.
11. Remove oil cooler pipe adaptors, fit them into
new intermediate plate.
12. Fit plugs and new seal rings into new
intermediate plate.
13. Fit intermediate plate assembly onto bell
housing.
14. Secure with six hexagonal bolts (outer ring
pattern). Tighten to
46 Nm.
15. Place intermediate plate and bell housing
assembly on bench, front face up.
16. Fit ’O’ ring onto circumference of pump housing.
17. Align dowel with hole in intermediate plate, press
pump housing home.
18. Secure pump housing to intermediate plate,
tighten eight bolts to
10Nm.
19. Place bell housing and intermediate plate
assembly on bench. Using oil pump rotation
sleeve LST111, check that pump gears rotate
freely.
20. Before replacing intermediate plate and bell
housing assembly check that thrust washer and
axial cage are seated on ’A’ clutch housing.
21. Place gasket and disc washer onto bell housing
and intermediate plate assembly using
Petroleum Jelly.
22. Fit bell housing and intermediate plate assembly
onto gearcase, tighten twelve bolts to
46 Nm.
23. Place end-float gauge LST111 on pump housing
and check that axial play is between 0,2-0,4 mm.
Renew existing washer, at rear of intermediate
plate, to give required end-float.
24. Refit torque converter into housing using torque
converter handles 18G1501. Check dimension
from converter fixing boss to converter housing
face is 50 mm. This shows converter is properly
seated in housing.
25. Refit gearbox/transfer box assembly.
See ZF
Auto with Borg Warner Transfer Gearbox
ZF
1
SPECIFICATIONS, TORQUE
TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
Coupling shaft to mainshaft
42*
. . . . . . . . . . . . . . . . . ..
Filler tube to sump
68
. . . . . . . . . . . . . . . . . . . . . .
Gear change lever to gearbox
25
. . . . . . . . . . . . . . . . ...
Cooler pipe adaptor to gearbox
42
. . . . . . . . . . . . . . . . .
Securing screws - clutch F
10
. . . . . . . . . . . . . . . . . . .
Securing screw - parking pawl
10
. . . . . . . . . . . . . . . . ...
Securing screws - pump
10
. . . . . . . . . . . . . . . . . . .
Intermediate plate plugs (M20)
50
. . . . . . . . . . . . . . . . ..
Intermediate plate plugs (M14)
40
. . . . . . . . . . . . . . . . ..
Bell housing mounting bolts
46
. . . . . . . . . . . . . . . . . ...
Governor mounting screws
10
. . . . . . . . . . . . . . . . . .
Extension housing bolts
23
. . . . . . . . . . . . . . . . . . . .
Control unit mounting bolts
8
. . . . . . . . . . . . . . . . . . .
Sump plug
10
. . . . . . . . . . . . . . . . . . . . . . . . ..
Mounting screws for sump
8
. . . . . . . . . . . . . . . . . . ..
Drive plate to converter
39*
. . . . . . . . . . . . . . . . . . . .
Gearbox to engine
42
. . . . . . . . . . . . . . . . . . . . . .
Strut (threaded end)
42
. . . . . . . . . . . . . . . . . . . . ...
Bottom cover to converter housing
9
. . . . . . . . . . . . . . . .
Cover - converter housing
9
. . . . . . . . . . . . . . . . . . ...
Drive plates to crankshaft adaptor
40*
. . . . . . . . . . . . . . .
Adaptor to crankshaft
84
. . . . . . . . . . . . . . . . . . . . .
NOTE: * These bolts must have threads coated with Loctite 270 prior to assembly.
Torque values below are for all screws and bolts used except for those that are specified otherwise.
METRIC
Nm
M5
6
. . . . . . . . . . . . . . . . . . . . . . . . . ..
M6
9
. . . . . . . . . . . . . . . . . . . . . . . . . ..
M8
25
. . . . . . . . . . . . . . . . . . . . . . . . . .
M10
45
. . . . . . . . . . . . . . . . . . . . . . . . ...
M12
90
. . . . . . . . . . . . . . . . . . . . . . . . ...
M14
105
. . . . . . . . . . . . . . . . . . . . . . . . ..
M16
180
. . . . . . . . . . . . . . . . . . . . . . . . ..
UNC / UNF
1/4
9
. . . . . . . . . . . . . . . . . . . . . . . . . ..
5/16
24
. . . . . . . . . . . . . . . . . . . . . . . . ...
3/8
39
. . . . . . . . . . . . . . . . . . . . . . . . . .
7/16
78
. . . . . . . . . . . . . . . . . . . . . . . . ...
1/2
90
. . . . . . . . . . . . . . . . . . . . . . . . . .
5/8
136
. . . . . . . . . . . . . . . . . . . . . . . . .
44
AUTOMATIC GEARBOX
2
SPECIFICATIONS, TORQUE
ZF GEARBOX DATA
Axial end float 0.2 to 0.4 mm.
From torque converter boss to torque converter
housing face 50 mm
Freewheel cage assembly to ring gear; minimum
clearance 0.1 mm
Output shaft above cylinder F assembly; dimension
10.00 mm
A cylinder protrusion above gearbox front face not
more than 8.5 mm
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