1995 LAND ROVER DISCOVERY gearbox

44AUTOMATIC GEARBOX
6
FAULT DIAGNOSIS 1. A Clutch assembly
2. B Clutch assembly

44AUTOMATIC GEARBOX
8
FAULT DIAGNOSIS 1. Freewheel and fourth gear assembly

44AUTOMATIC GEARBOX
10
FAULT DIAGNOSIS FAULT SYMPTOMS
SYMPTOM 1 - Intermittent drive and high pitched
noise
FAULT - Low fluid level or restricted filter
SYMPTOM 2 - No drive in reverse
Select 'D'
ú No drive
FAULT - Continue with Symptom 3
ú Drives forward
FAULT - Reverse gear interlock valve
seized
Select '1'
ú No engine braking
FAULT - Clutch brake 3
SYMPTOM 3 - No drive from rest with 'D' selected
Select '1'
ú Vehicle drives
FAULT - No 2 freewheel
ú No drive
Carry out main line pressure check
ú Normal pressure
FAULT - Clutch A
ú No pressure
FAULT - Blocked filter or pump failure
ú Low pressure
FAULT - Restricted filter or sticking primary
regulator
SYMPTOM 4 - Slip in all forward gears
Carry out main line pressure check
ú No pressure
FAULT - Blocked filter or pump failure
ú Low pressure
FAULT - Restricted filter or sticking primary
regulator
ú Normal pressure
FAULT - Clutch 'A'SYMPTOM 5 - Harsh engagement 'N' to 'D'
Check engine idle speed
Carry out main line pressure check
ú High pressure
FAULT - Primary regulator stuck
ú Normal pressure
FAULT - Clutch 'A' or damper for clutch'A'
SYMPTOM 6 - Fierce shift or flare 1st to 2nd shift
Check engine idle speed
Carry out mainline pressure check
ú High pressure
FAULT - Continue with symptom 5
ú Normal pressure
FAULT - Modulator valve or dampers for
clutch brake CB1 and/or clutch brake CB2
FAULT - Clutch brake CB1 and/or clutch
brake CB2
SYMPTOM 7 - Fierce shift or flare 2nd to 3rd
Carry out mainline pressure check
ú High pressure
FAULT - Continue with symptom 5
ú Normal pressure
FAULT - Modulator valve or clutch 'B'
damper
FAULT - Clutch 'B'
SYMPTOM 8 - No 3rd gear
FAULT - 2-3 shift valve
FAULT - Clutch 'B'
SYMPTOM 9 - No 4th gear 'D' selected
FAULT - 4th to 3rd downshift valve stuck or
3rd to 4th upshift valve stuck
FAULT - Clutch brake 4

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.

44AUTOMATIC GEARBOX
2
REPAIR 1.Site vehicle on a four post ramp [hoist].
2.Disconnect battery negative lead.
3.Remove fan cowl securing screws and release
cowl from radiator.
4.Loosen securing clip and disconnect air flow
hose from plenum chamber.
5.Disconnect stepper motor hose from top of
plenum chamber.
6.Disconnect kickdown cable from throttle linkage
and release from clipping.7.Release two gearbox breather pipes from clip
located on lifting eye at rear of right hand
cylinder head.
8.Remove dipstick from main gearbox oil filler
tube.
9.Working inside vehicle detach transfer gear lever
gaiter from console, unscrew knob and withdraw
gaiter and knob.
10.Raise vehicle on ramp [hoist].
11.Remove drain plugs and drain oil from transfer
gearbox and main gearbox. Refit plugs.
12.Detach heat shield at front exhaust pipe to
manifold.
13.Disconnect electrics to Lambda sensors.
14.Remove catalytic converter assembly.
15.Remove chassis cross-member from under
gearbox.16.Remove heat shield from speedometer cable at
transfer gearbox.
17.Remove clamp and disconnect speedometer
cable from transfer gearbox. Tie cable to one
side.
18.Mark for reassembly propeller shaft to transfer
gearbox mating flanges.

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.

ZF
5
REPAIR Remove
1.Select low range with transfer gear lever.
2.Remove knob and gaiter from transfer gear
lever.
3.Disconnect battery terminals.
4.Remove insulation pad from rocker cover and
inlet manifold.
5.On LH drive vehicles only, disconnect multi-plug
from top of brake fluid reservoir.
6.Release electrical harness from clips along top
of bulkhead and pull over to one side.7.Remove bolt securing transfer and main gearbox
breather pipe clip to rear of cylinder head.
8.Disconnect kick down cable at fuel injection
pump.
9.Drain coolant from cooling system.
10.Disconnect top hose from radiator.
11.Disconnect turbo charger hose from inter-cooler.
12.Remove starter heat shield.