1995 LAND ROVER DISCOVERY transmission

ZF
1
DESCRIPTION AND OPERATION DESCRIPTION
The automatic transmission is specially tailored version of the ZF4 HP22, used by many manufacturer's of high
performance vehicles.
A three element torque converter delivers the power to a four speed epicyclic transmission. First, second and third
gears are reduction ratios but fourth is an overdrive gear for high speed cruising. A direct drive clutch, integral with
the torque converter operates to engage fourth gear.
The gear selector has seven positions as follows:
P = Park provides a mechanical lock on the output shaft.
R = Reverse gear.
N = Neutral.
D = Provides a 1st gear start and automatic shifts 1-2-3-4-3-2-1.
3 = Provides a 1st gear start and automatic shifts 1-2-3-2-1.
2 = Provides a 1st gear start and automatic shifts 1-2-1 or 3-2-1.
1 = Provides a 1st gear start with no up shifts, or 3-2-1.
All automatic shifts are automatically controlled by the valve block and an hydraulic governor driven by the output
shaft.

ZF
1
REPAIR LT230T TRANSFER GEARBOX WITH AUTOMATIC
GEARBOX ASSEMBLY - V8i
Service repair no - 44.20.04
Removal from V8i engine
The assembled transfer gearbox, automatic gearbox
and torque converter is removed from underneath the
vehicle. Use a transmission hoist with an adaptor
plate for securing the assembly to the hoist. The
adaptor can be manufactured locally to the drawing
below or purchased from:- Straight Set Engineering,
England. Tel.01909 480055
WARNING: When using a transmission
hoist it is essential to follow the hoist
manufacturer's instructions.

ZF
3
REPAIR 19.Disconnect rear propeller shaft to output flange,
and tie to one side.
20.Repeat instructions 18 and 19 on front propeller
shaft to main gearbox.
21.Remove bolts retaining silencer front and rear
securing brackets and tie silencer to one side.
22.Disconnect oil cooler feed and return pipes from
bottom and side of main gearbox.
23.Release cooler pipes from clamp at engine sump
and remove distance piece.
24.Blank pipe ends and unions.
25.Move oil cooler pipes clear of transmission and
tie aside.
26.Disconnect selector cable from operating lever.
27.Disconnect inhibitor switch at multiplug.
28.Attach adaptor plate to hoist.
29.Remove two bolts from transfer gearbox rear
cover.
30.Raise hoist to align adaptor plate with transfer
gearbox and transmission. Secure to transfer
gearbox at rear cover with two bolts removed.
31.Adjust hoist to take weight of transmission.
32.Remove nuts and bolts securing right transfer
gearbox mounting bracket to chassis.
33.Repeat for the left mounting bracket. Removal of
these fixings will also free speedometer
transducer bracket
34.Remove right side mounting bracket to flexible
mounting rubber retaining nut.
35.Lower hoist until rear brake drum clears
passenger footwell. Check engine does not
crush any components while lowering.
36.Remove clip and clevis pin from park brake
lever.
37.Remove clip securing outer brake cable
38.The park brake cable is now free.
39.Disconnect leads from transfer gearbox
temperature sensor and differential lock warning
light switch.
40.Remove ties securing breather pipes to harness.
41.Remove bell housing access plate complete with
gasket.
42.Rotate engine, using crankshaft pulley, until two
access holes are visible in drive plate/ring gear
assembly through bell housing bottom cover
opening.
43.Identify an access hole and bolt hole to aid
reassembly.
44.Remove bolts securing drive plate to convertor
through access holes.
45.Rotate crankshaft half turn to access and
remove remaining bolts.
46.Disconnect oil dipstick tube at main gearbox.
47.Remove bolt at bell housing and detach dipstick
tube. Blank pipe end and union.
48.Position hoist jack channel under engine and
support using a wooden block.
49.Remove bell housing to engine securing bolts,
also detach harness bracket from bell housing.
50.Ease transmission rearwards to allow access to
secure torque converter in bell housing.
51.Lower hoist and complete removal of
transmission.
Refit
52.Ensure torque converter is retained in bell
housing.
53.Secure transmission to adaptor plate on lifting
hoist.
54.Raise hoist and locate transmission with engine.
55.Remove torque converter retainer.
56.Complete attachment of transmission to engine
and fit bell housing bolts. Fit the dipstick tube
bracket and harness bracket to their respective
bolts.
57.Complete refitting by reversing removal
procedure. Note the following important points.
58.Drive plate to torque converter bolts are to be
coated with Loctite 290 prior to assembly.
59.Refill transfer and main gearboxes with correct
grade oil.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
60.Check operation of parking brake and adjust as
necessary.
See SECTION 10, Maintenance,
Vehicle Interior

44AUTOMATIC GEARBOX
4
REPAIR LT230T TRANSFER GEARBOX WITH AUTOMATIC
GEARBOX ASSEMBLY - Tdi
Service repair no - 44.20.04
Removal from Tdi engine
The assembled transfer gearbox, automatic gearbox
and torque converter is removed from underneath the
vehicle. Use a transmission hoist with an adaptor
plate for securing the assembly to the hoist.
WARNING: When using a transmission
hoist it is essential to follow the hoist
manufacturer's instructions.

44AUTOMATIC GEARBOX
6
REPAIR 13.Remove starter.
14.Working through starter aperture note position of
torque converter flexible drive plate to facilitate
refitting.
15.Remove the four torque convertor to flexible
drive securing bolts, rotating engine to gain
access to each individual bolt.
16.Raise vehicle on four post ramp [hoist].
17.Drain lubrication oil from transfer and main
gearboxes.
18.Disconnect speedometer cable from transfer
gearbox and disconnect associated clipping.
19.Remove rear propeller shaft.
See PROPELLER
SHAFTS, Overhaul, Flexible Coupling
20.Disconnect front propeller shaft at transfer
gearbox and tie to one side.
21.Remove exhaust front pipe.
22.Remove bolts securing front and centre silencer
mounting brackets and tie silencer to one side.
23.Disconnect oil cooler pipes from gearbox.
24.Blank off pipes and union connections.
25.Remove bolt securing retaining bracket to sump
and move cooler pipes aside.
26.Disconnect selector cable from lever on side of
gearbox.
27.Disconnect inhibitor switch multi-plug.
28.Disconnect park brake cable from linkage to park
brake lever.
29.Disconnect electrical connections from
differential lock switch on transfer gearbox.
30.Remove two lower bolts from transfer gearbox
input bearing support plate.
31.Assemble approved support cradle to
transmission hoist.32.Raise hoist and secure cradle to transfer
gearbox input bearing support plate using bolts
removed.
33.Disconnect gearbox mounting brackets from
chassis cross member.
34.Remove chassis cross member.
35.Lower transmission sufficiently to allow access
to items attached to top of gearbox.
36.Remove left hand gearbox mounting bracket
assembly.
37.Remove ties from breather pipes and harness.
38.Remove nut securing gearbox oil filler/dip stick
tube to bell housing.
39.Release union nut at gearbox sump and remove
filler/dipstick tube. Fit blanking plugs.
40.Support engine using a wooden block with a
suitable ramp [hoist] jack.
41.Remove nut securing kick down cable bracket to
bell housing.
42.Remove two bolts securing top of bell housing to
flywheel housing.
43.Remove nuts securing bell housing to flywheel
housing and withdraw transmission assembly
from engine.
44.Fit a suitable torque converter retaining strap to
the bell housing.
45.Remove hoist and transmission from under
vehicle.
46.Fit lifting eyes to transmission.
47.Using suitable chains and lifting tackle take
weight of transmission assembly.
48.Remove bolts securing transmission cradle to
transfer box and withdraw hoist complete with
cradle.
49.Refit bolts to cover plate.

ZF
7
REPAIR Accessories removal/fitting
If fitting a replacement transmission assembly to the
vehicle, remove the following items from the existing
assembly and fit to the replacement.
CAUTION: It is important to remove the
spacer from the extension shaft and fit
onto the replacement unit.
50.Breather pipe union and washers from main
gearbox.
51.Breather pipe, union and washers from transfer
gearbox.
52.Main gearbox selector lever.
53.RH mounting bracket assembly.
54.Oil cooler pipe unions.
55.Fit blanks to all apertures where unions have
been removed and blank off pipe ends.
Refit
1.Fit transmission to cradle and hoist.
2.Locate hoist under vehicle and remove torque
convertor retaining strap.
3.Ensure low range gear is engaged.
4.Apply approved sealant to bell housing face.
5.Carefully raise assembly, align bell housing with
flywheel housing and bring mating faces
together.
6.Fit nuts and bolts to secure transmission to
engine.
7.Locate electrical wiring and breather pipes to
position.
8.Secure kick down cable clip to bell housing.
9.Raise hoist sufficiently to take weight.
10.Remove block and jack from engine sump.
11.Fit filler/dipstick tube to gearbox sump and
secure bracket to bell housing.
12.Apply Loctite to torque convertor bolts
13.Working through starter aperture refit the four
torque convertor to flexible drive securing bolts,
rotating crankshaft to gain access to bolt
locations.
14.Refit starter and heatshield.
15.Secure breather pipes and harness with ties.
16.Fit left hand mounting bracket assembly to
gearbox.
17.Raise transmission and support with a suitable
ramp [hoist] jack.
18.Remove two bolts securing transmission to
cradle, lower hoist and remove from under
vehicle.
19.Apply Loctite to above bolts and fit to transfer
gearbox input bearing support plate.
20.Fit chassis cross member.21.Secure gearbox mounting brackets to chassis
cross member.
22.Remove ramp [hoist] jack.
23.Connect electrical leads to differential lock
switch.
24.Connect inhibitor switch multi-plug.
25.Connect selector cable to lever on side of
gearbox.
26.Connect oil cooler pipes to gearbox and secure
retaining bracket to gearbox sump.
27.Secure silencer to chassis and refit exhaust front
pipe.
28.Refit front propeller shaft to transfer gearbox.
29.Refit rear propeller shaft.
See PROPELLER
SHAFTS, Overhaul, Flexible Coupling
30.Connect speedometer cable to transfer gearbox.
31.Refill transfer gearbox with correct grade of
lubricating oil.
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information,
Recommended Lubricants and Fluids
32.Lower ramp [hoist] to ground level.
33.Reconnect turbo-charger hose to inter-cooler.
34.Reconnect top hose to radiator.
35.Refill cooling system with correct mixture of
coolant.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
36.Reconnect kick down cable to fuel injection
pump.
37.Secure breather pipe clip to rear of cylinder
head.
38.Engage harness with clips along top of
bulkhead.
39.On left hand drive vehicles only, connect
multi-plug to top of brake fluid reservoir.
40.Refit insulation pad to rocker cover and inlet
manifold, secure with oil filler cap.
41.Refit gaiter and knob to transfer gear lever.
42.Select high range gear.
43.Reconnect battery terminals.
44.Refill main gearbox with correct grade of
lubricating oil.
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information,
Recommended Lubricants and Fluids

44AUTOMATIC GEARBOX
8
REPAIR INHIBITOR SWITCH
Service repair no - 44.15.19
Remove
1.Site vehicle on a four post ramp [hoist].
2.Disconnect battery negative lead. Raise vehicle.
3.Disconnect inhibitor switch multi plug.
4.Remove inhibitor switch retaining plate.
5.Remove inhibitor switch.
6.Remove 'O' ring seal.
7.Clean inhibitor switch.
Refit
8.Clean mating face on casing.
9.Fit and lubricate new 'O' ring seal to switch.
10.Fit switch to casing.
11.Secure with retaining plate and bolt.
12.Connect multiplug to harness.
13.Reconnect battery and remove vehicle from
ramp [hoist].
SELECTOR SHAFT OIL SEAL
Service repair no - 44.15.34
Renew
1.Site vehicle on a four post ramp [hoist].
2.Disconnect battery negative lead.
3.Raise vehicle.4.Detach heat shield at front exhaust pipe to
manifold.
5.Disconnect electrics from Lambda sensors.
6.Remove catalytic converter assembly.
7.Remove chassis cross-member from under
gearbox.
8.Engage low range gear in the transfer gearbox.
9.Support transfer gearbox with a jack or
transmission hoist.
10.Remove transfer gearbox chassis mounting
bracket nuts and bolts. Note location of
speedometer cable bracket for refit.
11.Lower transmission to allow access to selector
shaft.
12.Remove selector lever from shaft.
13.Remove selector shaft seal from casing.
14.Clean selector shaft and seal mating faces.
15.Fit centre section of special tool LST 114 over
selector shaft.
16.Lubricate new oil seal and position seal on tool.
17.Fit tool outer sleeve and screw on nut to drive
seal into housing.
18.Remove tool from shaft.
19.Refit selector lever to shaft.
20.Raise transmission and secure mounting
brackets to chassis. Ensure speedometer cable
bracket is secured. Tighten bolts to
30Nm.
21.Remove support jack.
22.Refit chassis cross-member.
23.Refit catalytic converter assembly.
24.Connect electrics to Lambda sensors.
25.Connect heat shield front pipe to manifold.
26.Connect battery.
27.Check/top up gearbox oil level.

PROPELLER SHAFTS
1
DESCRIPTION AND OPERATION PROPELLER SHAFT ALIGNMENT
Description
The front and rear propeller shafts have non-constant
velocity 'Hooks' type universal joints, with needle roller
bearings. The bearing cups are pre-packed with
lubricant on assembly and a grease nipple is fitted for
servicing as specified, in maintenance section.
Both shafts have Rilsan coated sliding splines to
accommodate the variation in distance between the
axles and transmission. The splines are pre-packed
with lubricant and sealed.
The rear shaft is fitted with a conventional joint at
gearbox end and the sliding joint sealed with a rubber
gaiter. An SGF rubber coupling is fitted at the
differential end of the shaft.
The front shaft which is shorter than the rear is
'Phased', with the joints at each end, A and B
mis-aligned as shown in RR4199.
The phasing is necessary on the front shaft only to
allow for greater variation in angular changes.
Catalyst vehicles
The front shaft is 'phased' as above but is of solid bar
construction.