1999 LAND ROVER DISCOVERY lock

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-34 REPAIRS
25.Position gearbox support jack and secure tool
LRT-99-008A to support plate on jack.
26.Position a second support jack under engine
using a block between engine sump and jack to
prevent damage to sump.
27.Remove 4 bolts and nut, remove engine LH
rear mounting.
28.Remove 4 bolts and nut, remove engine RH
rear mounting. 29.Remove bolt securing gearbox oil cooler pipe
clips to engine.
30.Remove bolt and 2 nuts securing clamps to oil
cooler pipes and remove clamps.
31.Loosen gearbox oil cooler pipe unions, release
pipes from gearbox and discard 'O' rings.
CAUTION: Always fit plugs to open
connections to prevent contamination.

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-35
32.Remove 'C' clip securing selector cable to
gearbox bracket.
33.Remove nut securing selector lever to inhibitor
switch and release lever.
34.Disconnect multiplug from inhibitor switch.
35.Loosen gearbox multiplug locking ring and
disconnect plug.
36.Lower gearbox sufficiently to access bell
housing bolts, take care not to trap any pipes or
cables when lowering gearbox.
37.Remove 14 bolts securing gearbox to engine.
38.With assistance remove gearbox from engine.39.Fit suitable strap to retain torque converter.
Refit
1.Clean gearbox to engine mating faces.
2.Remove torque converter retaining strap.
3.With assistance position gearbox to engine.
4.Fit gearbox bell housing bolts and tighten to 46
Nm (34 lbf.ft)..
5.Connect multiplug to gearbox and tighten
locking ring.
6.Connect inhibitor switch multiplug.
7. If fitted: Connect and adjust differential lock
selector cable.

+ TRANSFER BOX - LT230SE,
ADJUSTMENTS, Cable - selector -
differential lock - adjust.
8.Position selector lever to inhibitor switch and
tighten nut to 25 Nm (18 lbf.ft).
9.Position selector cable to gearbox and secure
with 'C' clip.
10.Clean oil pipe unions and fit new 'O' rings.
11.Position and tighten pipe unions to gearbox.
12.Position and tighten oil cooler pipe clamps.
13.Position and tighten oil cooler pipe clip to
engine sump.
14.Position engine RH and LH rear mountings
and tighten bolts to 85 Nm (63 lbf.ft) and nuts to
85 Nm (63 lbf.ft).
15.Secure gearbox breather pipes to bulkhead
clip.
16. Up to 03 Model Year - If fitted: Connect 2
Lucars to differential lock warning lamp switch
and multiplugs to high/low ratio switch and
neutral sensor.
17. 03 Model Year onwards - If fitted: Connect
differential lock warning lamp switch multiplugs
to main harness.
18.Position cable tie and multiplug to transfer
gearbox bracket.
19.Connect high/low ratio selector cable to
selector lever and secure with clevis pin.
20.Position high/low ratio selector cable to
abutment bracket and secure with 'C' clip.

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-36 REPAIRS
21. Models fitted with high/low shift interlock
solenoid: Position interlock solenoid harness
to high/low shift cable, fit sleeve around cable
and harness, secure sleeve.
22. Models fitted with high/low shift interlock
solenoid: Connect solenoid multiplug to main
harness and secure multiplug to bracket.
23.Position hand brake back plate and tighten
bolts to 75 Nm (55 lbf.ft).
24.Fit hand brake drum and tighten screw.
25.Remove bolts securing tool LRT-99-008A to
gearbox.
26.Rotate engine to align torque converter, fit new
bolts and tighten to 50 Nm (37 lbf.ft).
27.Fit access plug to torque converter housing.
28.Fit rear propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.
29.Fit front propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
30.Fill transfer gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
31.Fill automatic gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
32.Position intermediate silencer and secure to
mounting rubbers.
33.Clean silencer and tail pipe mating faces.
34.Position new gasket to tail pipe and tighten nuts
to 40 Nm (30 lbf.ft).
35.Fit exhaust front pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Front pipe.
36.Position centre cross member, fit bolts and
tighten to 26 Nm (19 lbf.ft).
37.Connect battery earth lead.
38.Fit battery cover and secure fixings.
39.Check and adjust selector cable.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, ADJUSTMENTS, Cable - selector.

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-46 REPAIRS
Parking pawl assembly.
$% 44.28.07
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 and discard 9 bolts securing extension
housing to gearbox case.
4.Remove extension housing and discard gasket. 5.Remove Torx screw and discard, lift off parking
pawl guide and guide plate.
6.Remove ratchet, spring and pivot pin.
7. Td5 models: Remove spacer from output
shaft.
8.Remove park lock gear.
9.Remove and discard 'O' ring from output shaft.
M44 1109B
97
8

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-47
Refit
1.Clean park lock components.
2.Lubricate and fit new 'O' ring to output shaft.
3.Position park lock gear on the output shaft.
4. Td5 models: Fit the spacer.
CAUTION: Ensure that spacer is fitted on
output shaft - Tdi Models only. If spacer is
omitted, park gear and speed sensor may
move out of position.
5.Position pivot pin, spring and ratchet.
6.Position parking pawl guide and guide plate,
tighten Torx screw to 10 Nm (8 lbf.ft).
7.Clean extension housing and gearbox case.
8.Position new gasket to gearbox case.
9.Position extension housing and tighten bolts to
25 Nm (18 lbf.ft).
10.Fit transfer gearbox.

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

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

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
Gasket - oil sump
$% 44.24.05
Remove
1.Raise vehicle on ramp.
2.Drain automatic gearbox oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
3.Remove 6 bolts and spacers securing oil sump
to gearbox, remove sump and discard gasket.
Refit
1.Clean oil sump and mating face.
2.Fit new gasket to oil sump, position sump to
gearbox.
3.Position spacers and tighten bolts to 8 Nm (6
lbf. ft).
4.Fill automatic gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
5.Lower vehicle.

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-51
Valve body assembly
$% 44.40.01
Remove
1.Remove gearbox oil filter.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Filter - oil.
2.Remove 2 bolts securing speed sensor
harness bracket to valve body.
3.Disconnect multiplug from gearbox housing.
4.Using a 30 mm socket, remove nut securing
multiplug connector block to gearbox housing. 5.Remove 6 long bolts securing valve body to
gearbox.
6.Remove 5 short bolts securing valve body to
gearbox.

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-52 REPAIRS
7.Release speed sensor and remove valve body.
8.Remove and discard 'O' ring from multiplug
connector. Refit
1.Clean valve body and mating faces.
2.Fit new 'O' ring to multiplug connector block.
3.With assistance, position multiplug to gearbox
housing and tighten nut.
4.Align valve body to gearbox, ensure manual
valve is correctly located. Position speed
sensor retaining bracket, and tighten screws
to 8 Nm (6 lbf.ft).
5.Connect multiplug to gearbox connector.
6.Fit gearbox oil filter.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Filter - oil.

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-55
Lock-up solenoid valve (MV 3)
$% 44.15.35
Remove
1.Remove valve body assembly.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Valve body assembly.
2.Disconnect multiplug from lock-up solenoid
valve and release harness from clip.
3.Remove Torx screw and retaining fork securing
solenoid valve to valve body.
4.Remove solenoid valve from valve body.Refit
1.Clean lock-up solenoid valve with lint free cloth.
2.Position solenoid valve in valve body.
3.Position retaining fork, fit and tighten Torx
screw to 8 Nm (6 lbf.ft).
4.Connect multiplug to lock-up solenoid valve
and secure harness in clip.
5.Fit valve body assembly.
+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Valve body assembly.
M44 1354A
2
3
4