1999 LAND ROVER DISCOVERY gearbox

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-38 REPAIRS
Housing - torque converter
$% 44.17.01
Remove
1.Remove torque converter oil seal.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Torque converter and oil
seal.
2.Remove 18 bolts and plain washers securing
torque converter and intermediate plate to
gearbox casing. Note the position of the 4 bolts
that have sealant applied to the bolt threads
and 6 bolts, (outer ring), which are shorter.
3.Hold input shaft in position and carefully
remove the converter housing and intermediate
plate from gearbox casing.
4.Note the position of the Torrington race on the
forward clutch hub and the thrust washer which
will stay attached to the intermediate plate by
fluid adhesion.
5.Remove and discard intermediate plate gasket.
6.Remove thrust washer from intermediate plate.
7.Separate converter housing from intermediate
plate.Refit
1.Clean converter housing, intermediate plate
and gearbox casing mating faces.
2.Clean bolts and plain washers and sealant from
4 bolt threads.
3.Apply Petroleum Jelly to new gasket and
position on gearbox casing.
4.Apply Petroleum Jelly to thrust washer and
Torrington race.
5.Correctly position Torrington race and thrust
washer to forward clutch hub.
6.Position intermediate plate and converter
housing to gearbox casing.
7.Apply sealant, Part No. STC 50553 to 4 longer
bolt threads and fit bolts in the positions shown.
8.Fit remaining bolts and tighten progressively in
a diagonal sequence to 46 Nm (34 lbf.ft).
9.Place LRT-44-003/1 into pump housing, tighten
screws to secure LRT-44-003/1 to input shaft.
10.Clamp a suitable steel base to converter
housing flange.
11.Mount DTI gauge and position gauge probe
onto LRT-44-003/1 and zero gauge.
M44 1343
M44 1345
M44 1343
M44 1358
LRT-44-003/1

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-39
12.Check that the axial end-float is between 0.2 to
0.4 mm. If end-float is not within limits, replace
existing thrust washer, positioned at rear of
intermediate plate, with a suitable thickness
thrust washer to give the required end-float.
13.Remove DTI gauge and base plate.
14.Fit torque converter oil seal.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Torque converter and oil
seal.
Gasket - intermediate plate
$% 44.20.11
Remove
1.Remove torque converter oil seal.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Torque converter and oil
seal.
2.Remove 12 bolts and plain washers securing
converter housing and intermediate plate to
gearbox casing. Note the position of the 4 bolts
that have sealant applied to the bolt threads.
3.Hold input shaft in position and carefully lift off
converter housing and intermediate plate as an
assembly. Note the position of the Torrington
race on the forward clutch hub, and the thrust
washer which will stay attached to the
intermediate plate by fluid adhesion.
4.Remove and discard intermediate plate gasket.
5.Remove thrust washer from intermediate plate.
M44 1344
M44 1345

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-40 REPAIRS
Refit
1.Clean intermediate plate and mating face on
gearbox casing.
2.Apply Petroleum Jelly to new gasket and
position on gearbox casing.
3.Apply Petroleum Jelly to thrust washer and
Torrington race.
4.Correctly position Torrington race and thrust
washer to forward clutch hub.
5.Position converter housing and intermediate
plate assembly to gearbox casing.
6.Clean bolts and plain washers and old sealant
from 4 bolt threads.
7.Apply sealant, Part No. STC 50553 to 4 longer
bolt threads and fit bolts in position shown.
8.Fit remaining bolts and tighten progressively in
a diagonal sequence to 46 Nm (34 lbf.ft).
9.Place LRT-44-003/1 into pump housing, tighten
screws to secure LRT-44-003/1 to input shaft.
10.Clamp a suitable steel base to converter
housing flange.11.Mount DTI gauge and position gauge probe
onto LRT-44-003/1 and zero gauge.
12.Check that the axial end-float is between 0.2 to
0.4 mm (0.008 to 0.016 in). If end-float in not
within limits, replace existing thrust washer,
positioned at rear of intermediate plate, with a
suitable thickness thrust washer to give the
required end-float.
13.Remove DTI gauge and base plate.
14.Fit torque converter oil seal.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Torque converter and oil
seal.
M44 1344
M44 1358
LRT-44-003/1

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-41
Intermediate plate
$% 44.17.20
Remove
1.Remove intermediate plate gasket.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Gasket - intermediate plate.
2.Remove selective thrust washer from
intermediate plate.
3.Remove 2 M14 Allen plugs from intermediate
plate, remove and discard sealing washers.
4.Remove 2 M20 plugs from intermediate plate,
remove and discard sealing washers.
5.Remove 2 oil cooler pipe adaptors from
intermediate plate.
6.Remove 8 bolts securing fluid pump to
intermediate plate and carefully remove pump
from intermediate plate.7.Note position and remove pump locating dowel.
8.Remove and discard 'O' ring from pump
housing.
9.Remove 6 bolts securing converter housing to
intermediate plate, and release intermediate
plate from converter housing.
2443
M44 1356
3
M44 1336
M44 1341
M44 1357

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-42 REPAIRS
Refit
1.Clean intermediate plate and mating faces with
a lint free cloth.
2.Position intermediate plate to converter
housing, fit bolts and tighten evenly to 46 Nm
(34 lbf.ft)
3.Fit new sealing washers to M14 Allen plugs, fit
plugs and tighten to 40 Nm (30 lbf.ft).
4.Fit new sealing washers to M20 plugs, fit plugs
and tighten to 50 Nm (37 lbf.ft).
5.Fit oil cooler adaptors and tighten to 42 Nm (30
lbf.ft)
6.Clean pump housing and mating face on
intermediate plate with lint free cloth.
7.Lubricate new 'O' ring with transmission fluid
and fit to pump housing.
8.Position pump locating dowel into intermediate
plate.
9.Align pump to dowel and position in
intermediate plate.
10.Fit bolts and tighten in a diagonal sequence to
10 Nm (7 lbf.ft)
11.Position LRT-44-003/1 into pump and check
that the pump rotors turn freely.
12.Fit intermediate plate gasket.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Gasket - intermediate plate.
M44 1342
LRT-44-003/1

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-43
Pump - fluid
$% 44.32.01
Remove
1.Remove intermediate plate gasket.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Gasket - intermediate plate.
2.Remove 8 bolts securing fluid pump to
intermediate plate and carefully remove pump
from intermediate plate.
3.Note position and remove pump locating dowel.
4.Remove and discard 'O' ring from pump
housing.Refit
1.Clean pump housing and mating face on
intermediate plate with lint free cloth.
2.Lubricate new 'O' ring with transmission fluid
and fit to pump housing.
3.Position pump locating dowel into intermediate
plate.
4.Align fluid pump to dowel and position in
intermediate plate.
5.Fit bolts and tighten in a diagonal sequence to
10 Nm (7 lbf.ft)
6.Position LRT-44-003/1 into pump and check
that the pump rotors turn freely.
7.Fit intermediate plate gasket.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Gasket - intermediate plate.
M44 1336
M44 1341
M44 1342
LRT-44-003/1

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-44 REPAIRS
Seal - rear extension housing
$% 44.20.18
Remove
1.Remove transfer box

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - Diesel.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - V8.
2.Drain automatic gearbox oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
3.Remove rear extension housing oil seal from
gearbox. Refit
1.Clean oil seal recess in gearbox and running
surface on input shaft.
2.Lubricate oil seal running surface with
transmission oil.
3.Using tool LRT-44-001 fit oil seal to extension
housing.
4.Fit transfer box

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - Diesel.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - V8.
5.Fill automatic gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-45
Gasket - rear extension housing.
$% 44.20.19
Remove
1.Drain automatic gearbox oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
2.Remove transfer gearbox.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - Diesel.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - V8.
3.Remove 9 bolts securing rear extension
housing to gearbox case and remove housing.
4.Remove and discard gasket. Reassembly
1.Clean rear extension and mating face.
2.Position new gasket to gearbox case.
3.Position rear extension housing and tighten
bolts to 25 Nm (18 lbf.ft).
4.Fit transfer gearbox.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - Diesel.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - V8.
5.Fill automatic gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.