1995 LAND ROVER DISCOVERY check oil

ZF
13
REPAIR KICKDOWN CABLE
Service repair no - 44.15.01
Remove
1.Site vehicle on a four post ramp [hoist].
2.Select neutral 'N' gear lever.
3.Disconnect battery negative lead.
4.Disconnect kickdown cable at throttle linkage.
5.Release outer cable locknut.
6.Disconnect cable from mounting bracket.
7.Release cable from bracket attached to cylinder
head.
8.Feed cable through to underside of vehicle.
9.Raise vehicle on ramp [hoist].
10.Drain oil and refit plug with new seal.
11.Detach heat shield at front exhaust pipe to
manifold.
12.Disconnect electrics from Lambda sensors.
13.Remove catalytic converter assembly.
14.Remove chassis cross-member from under
gearbox.
15.Disconnect dipstick tube at oil sump. Loosen
securing bolt at bell housing and move dipstick
aside.
16.Remove clamps securing oil sump. Note their
locations for refit, and withdraw sump.
17.Pull kickdown inner cable to fully open valve
cam. Wedge cam in this position.
18.Release cable from cam by pushing inner cable
into outer casing and detaching cable nipple
from cam.
19.Using special tool LST112 compress cable tangs
and remove cable from gearbox.
20.If cable is to be refitted remove 'O' ring seal and
clean cable assembly.
Refit
21.Fit new 'O' ring seal to cable and lubricate seal.
22.Fit cable to gearbox casing ensuring it is
correctly seated.
23.Fit inner cable nipple to its location on cam.
NOTE: When a new cable is fitted, to help
locate nipple to cam, introduce a curve
into the cable. Do not bend or kink cable.24.Remove wedge from cam and ensure nipple
remains engaged.
25.Feed free end of cable assembly into engine
compartment.
26.Refit oil pan using a new gasket.
27.Connect dipstick tube to oil sump and tighten
bolt at bell housing.
28.Refit chassis cross-member
29.Refit catalytic converter assembly
30.Connect electrics to Lambda sensors.
31.Connect heat shield front pipe to manifold.
32.Lower vehicle on ramp [hoist].
33.Fit cable to bracket at cylinder head.
34.Locate cable in mounting bracket, do not tighten
locknut.
35.Fit cable to throttle linkage.
36.Ensure throttle linkage is fully closed.
37.Adjust outer cable to achieve a gap of 0,25 to
1,25mm (dimension 'A') between end of outer
cable and crimped collar on inner cable.
38.Tighten locknuts and recheck gap.
NOTE: If fitting a new cable, and collar on
inner cable is loose, measure distance 'B'
on old cable. Crimp collar on new cable to
this dimension.
39.Reconnect battery negative lead.
40.Refill gearbox oil using correct grade of oil.
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended Lubricants and
Fluids

44AUTOMATIC GEARBOX
18
REPAIR REPLACING TORQUE CONVERTER
1.Remove gearbox and transfer box assembly.
See LT230T 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.Fit new torque converter using torque converter
handles 18G1501. Check dimension from
converter fixing boss to converter housing face is
50 mm. This shows converter is correctly seated
in housing.
4.Refit gearbox and transfer box assembly.
See
LT230T Transfer Gearbox
ELIMINATING LEAKS ON PUMP HOUSING
1.Remove gearbox and transfer box assembly.
See LT230T 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 and pump assembly,
discard gasket.
5.Remove eight hexagonal bolts on rear of pump.

ZF
19
REPAIR 6.Screw in two bolts, diagonally opposite each
other. Tap lightly using a soft headed mallet to
remove pump assembly from intermediate plate.
7.Remove shaft sealing ring and 'O' ring from
pump housing and discard.
8.Using oil seal replacer LST108 fit shaft seal ring
into pump housing.
9.Fit 'O' ring onto circumference of pump housing.
10.Align dowel with hole in intermediate plate and
press pump housing home.11.Fit pump housing to intermediate plate, tighten
eight bolts to
10 Nm.
12.Place bell housing and intermediate plate
assembly on bench, front face up. Using oil
pump rotation sleeve LST111, check that pump
gears rotate freely.
13.Before fitting intermediate plate and bell housing
assembly,check that thrust washer and axial
cage are seated on A clutch housing.
14.Place gasket and disc washer onto bell housing
and intermediate plate assembly using
Petroleum Jelly.
15.Fit bell housing and intermediate plate assembly
to gearcase. Tighten twelve bolts to
46 Nm.
16.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.
17.Refit torque converter into housing using torque
converter handles 18G1501, checking that
dimension from converter fixing bolt boss to
converter housing face is 50 mm. This shows
converter is properly seated in housing.
18.Refit gearbox/transfer box assembly.
See
LT230T Transfer Gearbox

44AUTOMATIC GEARBOX
20
REPAIR ELIMINATING LEAKS BETWEEN GEARBOX
HOUSING AND INTERMEDIATE PLATE
1.Remove gearbox and transfer box assembly.
See LT230T 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
LT230T Transfer Gearbox

ZF
21
REPAIR REPLACING PUMP
Service repair no - 44.32.01
1.Remove gearbox and transfer box assembly.
See LT230T 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. 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.

PROPELLER SHAFTS
1
FAULT DIAGNOSIS VIBRATION HARSHNESS
1.Check that the propeller shaft universal joints
and sliding splines are not siezed or worn and
that the shafts are correctly aligned.
NOTE: In the event that both shafts are
satisfactory, but the vibration/harshness is
still present, the transfer box operation
and balance of the road wheels should be
checked.
For transfer box operation.
See TRANSFER
GEARBOX, Fault diagnosis, LT230T Transfer Box
- Oil Leaks
For balance of road wheels.See WHEELS AND
TYRES, Repair, Wheel Balancing

REAR AXLE AND FINAL DRIVE
1
FAULT DIAGNOSIS FAULT DIAGNOSIS
Complaint - Oil leaks
An external leak of lubrication from the hub seals can
be caused by a faulty internal seal. For example, if the
internal seals which separate the differential from the
hubs are faulty and the vehicle is operating or parked
on an embankment. Oil from the differential may flood
one hub causing a leak and leave the differential
lacking lubrication.
When a seal is found to be leaking check the axle
ventilation system, as a blockage can cause internal
pressure to force oil past the seals.
See 'Description and Operation' for illustrations of oil
seal locations.
When investigating hub seal leaks check the grease
for dilution with oil. Check also the differential level
and oil for metal particles and the condition of internal
seals.
If the vehicle is driven in deep water with defective oil
seals, water may contaminate the lubricants and raise
the differential level giving a false impression that the
housing has been overfilled with oil.
Do not assume that a high oil level in the
differential is due to over filling or, that a low level
is because of an external leak.

51REAR AXLE AND FINAL DRIVE
4
OVERHAUL 35.Fit pinion outer bearing track to pinion housing.
Use service tools LRT-54-505 and LRT-54-507.
36.Fit pinion head bearing to pinion. Use service
tool LRT-54-502.
37.Fit pinion into its location without shims for
bearing pre-load.
38.Fit outer bearing, and spacer (front axle
differential only).
39.Fit driving flange, washer and nut.
40.Do not fit oil seal at this stage.
41.Tighten pinion flange nut until force required to
rotate pinion is
3Nmif new bearings are fitted.
This will pre-load bearings to check pinion height
dimension.
NOTE: If using original bearings, pre-load
figure is 1.5 Nm.
Drive pinion markings
NOTE: Markings on end face adjacent to
serial number are of no relevance to
servicing.
42.Figures marked on end face opposite to serial
number show in thousandths of an inch,
deviation from nominal, required to set pinion.
Pinions marked plus (+) must be set below
nominal. Pinions marked minus (-) must be set
above nominal. Unmarked pinions must be set at
nominal.