Range Rover Classic. Manual — part 79
44
AUTOMATIC GEARBOX
18
REPAIR
ELIMINATING LEAKS BETWEEN GEARBOX
HOUSING AND INTERMEDIATE PLATE
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, taking care not to damage torque
converter/oil pump housing oil seal.
3. Remove twelve hexagonal bolts (inner ring
pattern).
4. Remove bell housing/intermediate plate
assembly from gearbox case and discard
gasket.
5. Place new gasket onto intermediate plate using
Petroleum Jelly.
6. Before fitting bell housing assembly check that
thrust washer and axial cage are seated on A
clutch housing.
7. Fit bell housing assembly with disc washer to
gearcase. Tighten twelve bolts to
46Nm.
8. Place end-float gauge LST111 onto pump
housing and check that axial play is between
0.2-0.4 mm. Replace existing washer, situated at
rear of intermediate plate, with a suitable washer
to give required end-float.
9. Refit torque converter using torque converter
handles 18G1501. Checking that dimension
from converter fixing boss to converter housing
case is 50mm. This dimension shows converter
is properly seated.
10. Refit gearbox/transfer box assembly.
See ZF
Auto with Borg Warner Transfer Gearbox
ZF
19
REPAIR
REPLACING BELLHOUSING
Service repair no - 44.17.01
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, taking care not to damage torque
converter/oil pump housing oil seal.
3. Remove eighteen hexagonal bolts.
4. Remove bell housing.
5. Fit new bell housing.
6. Secure bell housing, tighten eighteen bolts to
46
Nm.
7. Refit torque converter using torque converter
handles 18G1501. Check that dimension from
converter fixing boss to converter housing face is
50 mm. This dimension shows converter is
properly seated in housing.
8. Refit gearbox/transfer assembly.
See ZF Auto
with Borg Warner Transfer Gearbox
44
AUTOMATIC GEARBOX
20
REPAIR
REPLACING PUMP
Service repair no - 44.32.01
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, taking care not to damage torque
converter/oil pump housing oil seal.
3. Remove twelve bolts (inner ring pattern).
4. Remove bell housing and pump assembly from
gearbox case, discard gasket.
5. Remove eight bolts on rear of pump.
6. Screw in two bolts,diagonally opposite each
other, tap lightly using a soft headed mallet to
free pump assembly from intermediate plate.
7. Fit new pump assembly, aligning dowel with hole
in intermediate plate, press pump housing home.
8. Secure pump housing to intermediate plate
using eight hexagonal bolts and. Tighten to
10
Nm.
9. Place bell housing and intermediate plate
assembly on bench, front face up. Using oil
pump rotation sleeve LST111, check that pump
gears rotate freely.
10. Before replacing intermediate plate/bell housing
assembly check that thrust washer and axial
cage are seated on A clutch housing.
11. Place new gasket and disc washer onto bell
housing and intermediate plate assembly using
a Petroleum Jelly.
12. Fit bell housing and intermediate plate assembly,
tighten twelve bolts to
46 Nm.
ZF
21
REPAIR
13. Place end-float gauge LST111 onto pump
housing and check that axial play is between
0.2-0.4 mm. Replace existing washer, situated at
rear of intermediate plate, with suitable washer
to give required end-float.
NOTE: If damage is apparent to bolts they
should be replaced.
14. Refit torque converter into housing using torque
converter handles 18G1501. Check dimension
converter fixing boss to converter housing face is
50 mm. This shows converter is properly seated
in housing.
15. Refit gearbox/transfer box assembly.
See ZF
Auto with Borg Warner Transfer Gearbox
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