1995 LAND ROVER DISCOVERY transmission fluid

GENERAL SPECIFICATION DATA
9
INFORMATION TRANSMISSION 3.9 V8i
Manual gearbox
Type R380 Single helical constant mesh.......................................................................
Speeds 5 forward 1 reverse all synchromesh.............................................................................
Clutch
Make and type Borg and beck diaphram type..................................................................
Clutch plate diameter 266.5mm........................................................
Automatic gearbox
Type ZF4HP Four speed and reverse with fluid torque converter.....................................................................
Transfer box
Type LT230T Two speed reduction on main gearbox output, front....................................................................
and rear drive permanently engaged via a lockable
differential.
Propeller shafts
Type
Front Tubular 51mm diameter.................................................................................
Front - Catalyst vehicles Solid bar 28.6mm diameter...................................................
Rear Tubular 51mm diameter.................................................................................
Universal joints Open type Hookes O3EHD.................................................................
Rear axle
Type Spiral bevel, fully floating shafts.................................................................................
Ratio 3.54:1.................................................................................
Front axle
Type Spiral bevel, enclosed constant velocity joints, fully.................................................................................
floating shafts
Angularity of universal joint on full lock 32° ............................
Ratio 3.54:1.................................................................................

GENERAL SPECIFICATION DATA
21
INFORMATION TRANSMISSION - 300 Tdi
Manual gearbox
Type R380 Single helical constant mesh.......................................................................
Speeds 5 forward 1 reverse all synchromesh.............................................................................
Automatic gearbox
Type ZF4HP Four speed and reverse with fluid torque converter.....................................................................
Transfer box
Type LT230T Two speed reduction on main gearbox output. Front....................................................................
and rear drive permanently engaged via a lockable
differential

MAINTENANCE
9
MAINTENANCE
CHECK CONDITION OF DRIVE BELT - V8i - Tdi -
Mpi
RENEW - V8i - Tdi
Renew drive belt V8i.See ENGINE, Repair, Drive
Belt Renew
Renew drive belt Tdi.See ENGINE, Repair, Drive
Belt Renew
RENEW - Mpi
1.Check condition of drive belt, renew a belt that
shows signs of wear, splitting or oil
contamination.
2.Check belt length indicator, belt must be
renewed before indicator reaches R.H. end of
slot.
3.Use 15mm ring wrench on bolt and hold
tensioner pulley fully clockwise.
4.Release drive belt from tensioner pulley and
remove ring wrench.
5.Remove belt from between pulleys.
6.Clean drive belt pulley grooves and ensure
grooves are not damaged.
7.Fit new drive belt around pulley, except
tensioner pulley, ensuring all grooves are
correctly engaged.
8.Hold tensioner pulley fully clockwise and fit drive
centrally around tensioner pulley.
RENEW ANCILLARY DRIVE BELTS
CHECK/TOP UP AUTOMATIC TRANSMISSION
FLUID LEVEL
NOTE: Transmission fluid level is checked
when fluid is cold with engine idling in
neutral.
1.Ensure vehicle is on level ground.
2.Check fluid level registers between MAX and
MIN marking on dipstick.

V8i
13
REPAIR
NOTE: Release bolts securing compressor
mounting bracket to engine and remove
bracket to enable temporary lifting eye
ETC 5964 to be fitted. Secure lifting eye to
mounting bracket fixing points with suitable bolts
of equivalent size, pitch and thread. Leave lifting
eye attached until engine is reinstalled in vehicle.
15.Place drain tray underneath vehicle.
16.Disconnect hose from reservoir to power
steering pump. Secure hose end above level of
fluid reservoir to avoid unnecessary loss of fluid.
17.Disconnect power steering pump to power
steering box hose. Seal hose and pump
openings with masking tape to prevent ingress of
dirt. Wipe away any fluid spillage from chassis or
steering box.
18.Disconnect fuel temperature and coolant
temperature sensor multi-plugs.
19.Disconnect leads from coil.
20.Identify each injector multi-plug for re-assembly
and disconnect plugs from injectors.
21.Manoeuvre harness from behind fuel rails and
place to one side clear of engine assembly.
22.Remove two clamps securing gearbox oil cooler
pipes to engine block.
23.Remove engine mounting fixings on both sides
of cylinder block.
24.Fit lifting chains to engine lifting eyes as shown
in illustration RR1780E.
1. L/H Front chain 356mm total overall length.
2. R/H Front chain 330mm total overall length.
3. R/H Rear chain 457mm total overall length.
NOTE: All chain dimensions are measured
from end of lifting hook to end of last link
in chain.
25.Fit chain lifting eye to a suitable engine hoist.
Raise hoist high enough to enable engine
mountings to be removed, and withdraw rubber
mountings.
26.Lower hoist until engine rests securely on engine
mounting brackets. Remove lifting chains and
hoist.
27.Disconnect two heater hoses located on top of
right hand rocker cover.
28.Remove ground strap from rear of left hand
cylinder head. DO NOT remove from retaining
clip.
29.Remove all electrical harnesses from retaining
clips at rear of engine.
30.Remove transmission breather pipes from
retaining clip on rear lifting eye.
31.Remove top two bolts securing bell housing to
cylinder block.
32.Raise front of vehicle, lower vehicle on to axle
stands.
33.Remove bell housing bottom cover. Remove
gasket from bell housing face.
34.Remove nuts securing exhaust downpipes to
manifolds, remove heat shield from right hand
side downpipe.
35.Remove electrical leads from starter motor
solenoid. Disconnect multi-plug from oil level
sensor on side of sump, if fitted.
NOTE: Instructions 37, 38 and 39 refer to
automatic vehicles only.
36.With assistance rotate engine at crankshaft
pulley until two access holes in drive plate/ring
gear assembly are visible.
37.Remove two bolts visible through access holes.
Mark one access hole and one bolt hole to
ensure unit is reassembled in its original position
38.Rotate crankshaft 180Ê until two remaining
access holes are visible, remove two bolts.

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

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

AIR CONDITIONING
3
REPAIR 5.Disconnect 2 pipe unions from oil cooler. Use a
second wrench to support hose adapter.
6.Remove transmission oil cooler. Seal
connections.
All models
7.Remove bolt securing receiver/drier clamp.
WARNING: Wear eye and hand protection
when disconnecting components
containing refrigerant. Plug all exposed
connections immediately.
8.Move receiver/drier just sufficiently to gain
access to pipe flange bolts without distorting the
pipes.
9.Remove bolt securing each pipe flange to
receiver/drier.
10.Disengage pipe flanges and withdraw
receiver/drier from mounting bracket.
11.Remove 'O' ring from each pipe flange.Refit
12.Fit new 'O' ring to each pipe flange, lubricate
with refrigerant oil.
13.Position receiver/drier in mounting bracket with
inlet and outlet connections correctly aligned.
14.Engage pipe flanges, fit bolts in turn and tighten.
15.Fit clamp bolt.
Automatic gearbox
16.Refit transmission oil cooler. Use a second
wrench to support pipe unions.
17.Check gearbox fluid level, top-up if necessary.
All models
18.Evacuate and recharge air conditioning system.
See Adjustment, Refrigerant Recovery
Recycling Recharging
19.Perform a leak test on disturbed joints.
20.Carry out a functional check.

86ELECTRICAL
34
REPAIR PRINTED CIRCUIT AND WARNING LIGHTS
1. Panel illumination bulbs
2. Transmission oil temperature warning lamp bulb
3. Hazard warning lamp bulb
4. Check engine warning lamp bulb
5. Handbrake/brake fluid warning lamp bulb
6. ABS warning lamp bulb
7. Headlamp main beam warning lamp bulb
8. Trailer direction warning lamp bulb9. Direction indicator warning lamp bulb
10. Air suspension warning lamp bulb
11. Ignition/no charge warning lamp bulb
12. Seat belt warning lamp bulb
13. Not used
14. Traction control warning lamp bulb
15. Diesel heater plug warning lamp bulb (if fitted)
16. Main printed circuit