1995 LAND ROVER DISCOVERY clutch

ZF
15
REPAIR GOVERNOR ASSEMBLY
Service repair no - 44.22.01
Remove
1.Remove transfer gearbox.
See TRANSFER
GEARBOX, Repair, LT230T Transfer Gearbox
2.Drain oil from automatic gearbox.
3.Remove bolts securing left hand mounting
bracket to extension housing and withdraw
bracket.
4.Remove transfer gear lever housing securing
bolts and move housing aside.
5.Remove extension housing ensuring seal is not
damaged, remove and discard gasket.
6.Remove extension shaft retaining bolt, withdraw
shaft and discard 'O' ring seal. If Tdi vehicle
remove spacer.
7.Remove governor assembly.
8.Remove park gear from governor assembly.
9.Detach governor housing.
10.Remove security clip and counter weight.
11.Remove and discard 'O' ring seal from output
shaft and three seal rings from 'F' clutch
housing.
12.Clean all components.
13.If necessary detach parking pawl by removing
guide plates and withdrawing mechanism.Refit
14.Refit parking pawl mechanism if removed.
15.Fit and lubricate new seal rings to 'F' clutch
housing shaft, ensure they are correctly seated.
16.Apply petroleum jelly to a new 'O' ring seal. Fit to
output shaft
17.Fit park gear to governor assembly tightening
screws to correct torque.
18.Fit governor assembly to output shaft.
19.Fit extension shaft with spacer if Tdi. Fit new 'O'
ring under bolt head.
20.Fit extension housing, avoid damaging seal.
Tighten to
23 Nm.
21.Refit transfer gear lever housing to extension
housing.
22.Refit mounting bracket to extension housing.
Tighten to
52 Nm.
23.Refit transfer gearbox.See TRANSFER
GEARBOX, Repair, LT230T Transfer Gearbox
24.Refill automatic gearbox with correct grade of oil.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids

44AUTOMATIC GEARBOX
16
REPAIR GOVERNOR HUB
Service repair no - 44.22.04
Remove
1.Remove transfer box.
See TRANSFER
GEARBOX, Repair, LT230T Transfer Gearbox
2.Remove transfer gear selector housing.
3.Loosen nine bolts holding extension housing.
4.Remove extension housing ensuring that seal is
not damaged, discard gasket.
5.Remove extension shaft and retaining bolt with
'O' ring. If Tdi vehicle remove spacer.
6.Remove governor assembly with parking wheel.
7.Remove two screws holding governor housing.
8.Remove two bolts, remove parking wheel.
Discard governor hub.
9.Remove security clip and counter-weight.
10.Remove 'O' ring from output shaft and discard.
11.Remove three seal rings from 'F' clutch housing
shaft.
12.Inspect all parts for damage or wear, replace if
necessary.
Refit
13.Fit counterweight and security clip into new
governor hub.14.Secure governor housing to governor hub.
Tighten to
10Nm.
15.Fit parking wheel to governor hub. Tighten to10
Nm.
16.Fit three new seal rings onto F clutch housing
shaft, fit 'O' ring onto output shaft.
NOTE: To aid fitting of 'O' ring apply
petroleum jelly.
17.Push governor assembly and parking wheel onto
output shaft until seated.
NOTE: Apply petroleum jelly to 'O' ring.
Ensure seal rings are snapped together
and seated.
18.Fit new gasket to rear of gearbox. Fit extension
housing, avoid damaging seal.
19.Fit extension shaft,and spacer if Tdi, apply
Loctite 270 to retaining bolt. Using a new 'O'
ring, tighten bolt to
42 Nm.
20.Tighten nine extension housing nine bolts to23
Nm.
21.Fit transfer gear selector housing, tighten three
bolts to
25 Nm.
22.Refit transfer box.

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.

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....................................................................................................

AIR CONDITIONING
3
DESCRIPTION AND OPERATION AIR CONDITIONING SYSTEM OPERATION
The air conditioning system provides the means of
supplying cooled and dehumidified, fresh or
recirculated air to the interior of the vehicle. The
cooling effect is obtained by blowing air through the
matrix of an evaporator unit and when required,
mixing that air with heated air by means of the heater
distribution and blend unit, to provide the conditions
required inside the vehicle. The volume of conditioned
air being supplied is controlled by a variable speed
blower.
A sealed system, charged with Refrigerant R134a,
together with a blower unit, blend unit and control
system combine to achieve the cooled air condition.
For air conditioning air distribution system.
See
HEATING AND VENTILATION, Description and
operation, Heating and ventilation unit
The air conditioning system comprises five major
units:
1.An engine-mounted compressor.
2.A condenser mounted in front of the radiator.
3.A receiver/drier unit located in front of the
condenser.
4.Thermostatic expansion valve mounted above
the evaporator.
5.An evaporator unit mounted in front of the heater
matrix.
NOTE: Vehicles fitted with rear air
conditioning have an additional
evaporator/blower motor assembly located
behind the LH rear compartment lower trim panel.
These units are interconnected by hoses and pipes
carrying Refrigerant R134a, the evaporator is linked
into the vehicle ventilation system.
Refrigeration cycle
1. Compressor
The compressor (1), belt driven from the crankshaft
pulley, pressurises and circulates the refrigerant
through the system. Mounted on the compressor, an
electro-mechanical clutch maintains the correct
temperature and pressure by engaging or disengaging
to support the system's requirements. The clutch
action is normally controlled by a thermostat located
at the evaporator (5). The compressor is of the
swashplate type having fixed displacement.Should the temperature at the evaporator (5) fall low
enough for ice to begin to form on the fins, the
thermostat disengages the clutch and also isolates the
cooling fans relays. When the temperature at the
evaporator (5) rises to the control temperature, the
clutch is re-engaged.
Should the system pressure become excessive or
drop sufficiently to cause damage to the compressor
(1) a dual pressure switch (7), located in the high
pressure line, signals the relay unit to disengage the
clutch. The compressor also has an emergency high
pressure relief valve (9) fitted.
The cooling fans are controlled by engine temperature
when the air conditioning is not switched on.
2. Condenser
From the compressor, hot high pressure vaporised
refrigerant (F1) passes to the condenser (2), which is
mounted in front of the engine coolant radiator. Ram
air(A1) passing through the condenser (2),
supplemented by 2 cooling fans (8) mounted in front
of the condenser, cools the refrigerant vapour
sufficiently to form a high pressure slightly subcooled
liquid (F2).
3. Receiver/drier
This liquid then passes to a receiver/drier (3) which
fulfils two functions. It acts as a reservoir and moisture
extractor (11).
A sight glass (10), in the high pressure line, provides a
method of determining the state of the refrigerant
without breaking into the system.
4. Expansion valve
From the receiver/drier (3) the moisture free high
pressure liquid refrigerant (F3) passes through a
thermostatic expansion valve (4). A severe pressure
drop occurs across the valve and as the refrigerant
enters the evaporator space at a temperature of
approximately -5°C it boils and vaporises.

82AIR CONDITIONING
4
DESCRIPTION AND OPERATION 5. Evaporator
As this change of state occurs, a large amount of
latent heat is absorbed. The evaporator is therefore
cooled and as a result heat is extracted from the air
flowing across the evaporator. The air flow is
controlled by the ventilation fan which can be
operated at anyone of four speeds.
To prevent liquid passing through to the compressor,
a capillary tube (6), attached to the outlet pipe of the
evaporator (5) and connected to the thermostatic
expansion valve (4), controls the amount that the
valve opens and closes in relation to the temperature
of the low pressure high temperature refrigerant
vapour (F4) at the outlet. The atomised refrigerant
then passes through the evaporator (5). Fan blown air
(A2) passes through the matrix (A3) of the evaporator
and is cooled by absorption due to the low
temperature refrigerant passing through the
evaporator.
A thermostat is fitted in the airflow out of the
evaporator to sense the temperature of the exterior
fins. Should ice begin to form, due to a too cold
condition, it will signal to disengage the
electro-mechanical clutch on the compressor (1).
From the evaporator, low pressure slightly
superheated refrigerant (F5) passes to the
compressor to complete the cycle.AIR CONDITIONING CONTROL SYSTEM
The air conditioning control system comprises relays,
thermostat, pressure switches, and a control panel.
Inputs from outside the air conditioning system
comprise temperature information from the engine
cooling system. Together these controls, in
conjunction with the cooling fans, compressor clutch,
blower and heater distribution and blend unit enable
minimal input to maintain the required environment
inside the vehicle.
When air conditioning is not selected, air is supplied
by ram effect or blower to the areas selected by the
controls. The air mix flap on the blend unit controls the
temperature of the air being supplied. No cooled air is
available.
Selecting air conditioning provides the added facility of
cooled air available to be mixed as before. When
required a fully cold condition can be selected by
turning the temperature controls to cold, which
automatically closes the heated coolant access to the
heater matrix. Mixtures of cooled, fresh, and hot air
can be selected to give required interior environmental
conditions by selection at the control panel.
Dual pressure switch
This switch, located in the high pressure line between
the receiver drier and the expansion valve, monitors
refrigerant pressure and by means of the relay module
controls the following system functions:
1.Refrigerant pressure drops below 2.0 bar, 29
lbf/in
2(due to possible leakage), the
compressor's electro-mechanical clutch is
dis-engaged.
When pressure rises above 2.0 bar, 29 lbf/in
2the
compressor's clutch is re-engaged.
2.Refrigerant pressure rises above 32 bar, 455
lbf/in
2(due to possible blockage), even with
cooling fan operation, the compressor's
electro-mechanical clutch is dis-engaged.
When the pressure drops below 26 bar, 375
lbf/in
2the compressor clutch is re-engaged.