1999 LAND ROVER DISCOVERY brake fluid

CLUTCH - V8
ADJUSTMENTS 33-2-11
ADJUST ME NTS
Clutch hydraulic system - bleed
$% 33.15.01
CAUTION: Ensure the fluid in the reservoir is
maintained between the minimum and maximum
levels throughout the bleed procedure using new
brake fluid.
CAUTION: Brake fluid will damage paint finished
surfaces. If spilled, immediately remove fluid and
clean area with water.
Bleeding
1.Top up reservoir.
2.Raise the front of the vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
3.Connect tube to bleed screw on clutch slave
cylinder and submerge free end in a clear
container containing brake fluid.
4.Loosen bleed screw, then apply steady
pressure to the clutch pedal, depressing it
through its full stroke. Allow the pedal to return
unassisted.
5.Repeat the procedure until a flow of clean, air-
free fluid is purged into the container.
6.Hold the pedal to the floor and tighten the
clutch bleed screw to 9 Nm (7 lbf.ft).
7.Check and top up reservoir.
CAUTION: Never re-use fluid that has been
bled from the system.
8.Remove stands and lower the vehicle.

CLUTCH - V8
33-2-14 REPAIRS
Master cylinder
$% 33.20.01
CAUTION: Brake fluid will damage paint finished
surfaces. If spilled, immediately remove fluid and
clean area with water.
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Release spring clip securing clutch pedal
clevis pin and remove pin from push rod and
clutch pedal.
3.Position container to catch spillage. Disconnect
hydraulic pipe from clutch master cylinder.
CAUTION: Always fit plugs to open
connections to prevent contamination.
4.Release clip and remove connecting hose from
clutch master cylinder.
5.Remove 2 bolts securing clutch master
cylinder to pedal box and remove clutch master
cylinder. Refit
1.Clean master cylinder and pedal box mating
faces.
2.Position clutch master cylinder to pedal box, fit
bolts and tighten to 25 Nm (18 lbf.ft).
3.Position clevis pin to push-rod and clutch pedal
and secure with spring clip.
4.Fit connecting hose to brake master cylinder
and tighten clip.
5.Position hydraulic pipe and tighten union to 18
Nm (13 lbf.ft).
6.Bleed clutch.

+ CLUTCH - V8, ADJUSTMENTS,
Clutch hydraulic system - bleed.
7.Remove stand(s) and lower vehicle.

AUTOMATIC GEARBOX - ZF4HP22 - 24
DESCRIPTION AND OPERATION 44-7
The gearbox consists of a torque converter housing, an intermediate plate, a gearbox housing and a rear extension
housing, bolted together in series. The rear of the gearbox is supported by a rubber mounting installed between a
mounting bracket on the gearbox and the LH chassis rail. A heat shield is installed on the mounting to protect it from
the exhaust.
Sectioned view of gearbox
1Lock-up clutch
2Impeller
3Turbine
4Forward drive clutch
5Reverse drive clutch
6Brake clutch
7Brake clutch
8Brake clutch
9Epicyclic gear set10Epicyclic gear set
11Clutch
12Brake clutch
13Output shaft
14Freewheel (one way clutch)
15Freewheel (one way clutch)
16Freewheel (one way clutch)
17Stator and one way clutch
Torque converter housing
The torque converter housing attaches the gearbox to the engine and contains the torque converter. Different torque
converter housings are used to accommodate the difference between the V8 and Td5 engine interfaces. The torque
converter is connected to the engine drive plate and transmits the drive from the engine to the gearbox input shaft.
When engaged, a hydraulic lock-up clutch in the torque converter prevents slippage, to give a direct drive from the
engine to the gearbox for improved driving response.
Intermediate plate
The intermediate plate supports the gearbox input shaft and provides the interface between the transmission fluid
pump and the lubrication circuit. The pump attaches to the front of the intermediate plate and is driven by the impeller
in the torque converter. The pump pressurises transmission fluid drawn from the sump on the gearbox housing. The
pressurised fluid then circulates through the torque converter and gearbox housing components for cooling,
lubrication and gear shift purposes. Ports around the outer periphery of the intermediate plate provide the inlet and
outlet connections to the fluid cooler and a pressure take-off point for servicing.

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-10 DESCRIPTION AND OPERATION
The lock-up and brake clutches are operated by pressurised transmission fluid from the valve block in the sump. A
manual valve and four solenoid valves, also known as Motorised Valves (MV), control the supply of pressurised
transmission fluid from the valve block:
lThe manual valve controls the supply in P, R, N and D.
lSolenoid valves MV 1 and MV 2 control the supplies that operate the brake clutches for shift control.
lSolenoid valve MV 3 controls the supply that operates the lock-up clutch.
lSolenoid valve MV 4 modulates the pressure of the supplies to the brake clutches, to control shift quality.
Operation of the manual valve is controlled by the selector lever assembly. In the gearbox, a selector shaft engages
with the manual valve. The selector shaft is connected to the selector lever assembly via the selector cable and a
selector lever on the left side of the gearbox. The selector shaft also operates a mechanism that locks the output shaft
when P is selected.
Operation of the solenoid valves is controlled by the EAT ECU.
An output shaft speed sensor in the gearbox housing outputs a signal to the EAT ECU. The EAT ECU compares
output shaft speed with engine speed to determine the engaged gear, and output shaft speed with vehicle speed to
confirm the range selected on the transfer box.
A bayonet lock electrical connector in the gearbox casing, to the rear of the selector lever, connects the solenoid
valves and the output shaft speed sensor to the vehicle wiring.
A pressed steel sump encloses the valve block and collects transmission fluid draining from the gearbox housing. A
suction pipe and filter on the underside of the valve block connect to the inlet side of the fluid pump. A magnet is
installed in the sump to collect any magnetic particles that may be present. A level plug and a drain plug are installed
in the sump for servicing.
Rear extension housing
The rear extension housing provides the interface between the gearbox housing and the transfer box. A splined
extension shaft, secured to the gearbox output shaft by a bolt, transmits the drive from the gearbox to the transfer
box. A seal in the rear of the housing prevents leakage past the extension shaft. A breather pipe, attached to the left
side of the rear extension housing, ventilates the interior of the gearbox and rear extension housings to atmosphere.
The open end of the breather pipe is located in the engine compartment at the right front corner of the engine sump
on gearboxes fitted to early vehicles and is clipped to the top of the gearbox on later vehicles.
Gearbox power flows
The following Figures show the power flow through the gearbox for each forward gear when D is selected, and for
reverse. The key to the Item numbers on the Figures, and in parenthesis in the accompanying text, can be found on
the 'Sectioned view of gearbox' Figure, above.
1st Gear (D selected)
Clutches (4) and (11) are engaged. The front planet gear carrier of gear set (9) locks against the gearbox housing
through freewheel (15) when the engine powers the vehicle, and freewheels when the vehicle is coasting. Gear set
(10) rotates as a solid unit with the front planet gear carrier. In 1st gear hold brake clutch (8) is applied to provide
overrun braking.

REAR AXLE
51-6 REPAIRS
10.Release and remove wheel hubs and drive
shafts from rear axle. Remove and discard 'O'
rings from wheel hubs.
11.Remove 10 bolts securing differential to axle.
Release and remove differential from axle. Refit
1.Clean drive shafts, wheel hubs and wheel hub
locations in rear axle.
2.Using a suitable solvent, remove all traces
sealant from differential and axle mating faces.
3.Apply sealant, Part No. STC 3811 to differential
or axle mating face.
4.Apply sealant, Part No. STC 50552 to threads
of differential securing bolts.
5.Fit differential to axle, fit bolts and tighten to 55
Nm (41 lbf.ft).
6.Clean pinion flange and centralising peg.
7.Using a tubular drift, fit centralising peg to
pinion flange. Ensure that the large diameter
part of the centralising peg is below pinion
flange mounting surface.
8.Position propeller shaft and align reference
marks.
9.Fit nuts and bolts securing flexible coupling to
pinion flange and tighten to 76 Nm (56 lbf.ft)
10.Lubricate 2 new wheel hub 'O' rings with clean
differential oil.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication. Install 'O' rings on wheel hubs.
11.Fit LH and RH drive shafts and wheel hubs to
rear axle. Fit wheel hub bolts and tighten to 100
Nm (74 lbf.ft).
12.Connect each ABS sensor multiplug and
secure harness to harness bracket and brake
hose.
13.Fit LH and RH rear brake discs.

+ BRAKES, REPAIRS, Brake disc -
rear.
14.Remove stand(s) and lower vehicle.
15.Fill differential with oil.

+ MAINTENANCE, PROCEDURES,
Front and rear axle.
M51 0042B

FRONT AXLE
54-6 REPAIRS
9.Remove 4 bolts securing each front wheel hub
to front axle.
10.Release wheel hubs from front axle. Remove
wheel hubs and drive shafts from front axle.
11.Remove oil seal from axle casing.
12.Remove 10 bolts securing differential to axle
casing. Release and remove differential from
axle casing.Refit
1.Clean drive shaft oil seal recess, oil seal
running surface, wheel hub and axle mating
faces.
2.Using a suitable solvent, remove all traces
sealant from differential and axle mating faces.
3.Applysealant, Part No. STC 3811 to differential
or axle mating face.
4.Apply sealant, Part No. STC 50552 to threads
of differential securing bolts.
5.Fit differential to axle, fit bolts and tighten to 55
Nm (41 lbf.ft).
6.Position propeller shaft and align reference
marks. Fit bolts and tighten to 47 Nm (35 lbf.ft).
7.Lubricate oil seal lip and running surface with
clean differential oil.
+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
8.Using LRT-54-012 and LRT-99-003, fit new
drive shaft oil seal to axle casing.
9.Apply anti-seize compound to wheel hub and
steering knuckle mating faces.
10.Ensure ABS harnesses are located in cut out in
steering knuckles.
11.Fit drive shafts in axle casing and align wheel
hubs with steering knuckles. Fit wheel hub bolts
and tighten to 100 Nm (74 lbf.ft).
12.Connect each ABS sensor multiplug and
secure harness to harness bracket and brake
hose.

FRONT AXLE
54-10 REPAIRS
9.Remove oil seal from axle casing.Refit
1.Clean drive shaft oil seal recess, oil seal
running surface, wheel hub and swivel hub
mating faces.
2.Lubricate oil seal lip and running surface with
clean differential oil.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
3.Using tool LRT-54-012 and tool LRT-99-003,
fit new drive shaft oil seal to axle casing.
4.Apply anti-seize compound to wheel hub and
steering knuckle mating faces.
5.Ensure ABS harness is located in cut out in
steering knuckle.
6.Fit drive shaft and wheel hub to axle casing and
align wheel hub with steering knuckle. Fit wheel
hub bolts and tighten to 100 Nm (74 lbf.ft).
7.Connect ABS sensor multiplug and secure
harness to harness bracket and brake hose.
8.Fit front brake disc.

+ BRAKES, REPAIRS, Brake disc -
front.
9.Fit road wheel and tighten nuts to 140 Nm (103
lbf.ft).
10.Remove stand(s) and lower vehicle.
11.Check differential oil level.

+ MAINTENANCE, PROCEDURES,
Front and rear axle.

FRONT SUSPENSION
60-4 DESCRIPTION AND OPERATION
Description
General
The front suspension comprises two dampers and coil springs, two radius arms, a Panhard rod and an anti-roll bar.
The front axle provides the location points for the dampers, springs, radius arms and the Panhard rod.
The anti-roll bar assembly is an essential part of the front suspension. On vehicles without Active Cornering
Enhancement (ACE) a conventional 'passive' anti-roll bar is fitted. On vehicles fitted with the ACE system, a thicker
diameter anti-roll bar, known as a torsion bar, is used with an actuator at one end.

+ FRONT SUSPENSION, DESCRIPTION AND OPERATION, Description - ACE.
The hydraulic dampers and coil springs provide springing for each front wheel. The long travel dampers, springs and
radius arms provide maximum axle articulation and wheel travel for off-road driving. The front axle is controlled
longitudinally by two forged steel radius arms and transversely by a Panhard rod.
Radius arms
Each radius arm is manufactured from forged steel. Two bushes are pressed into the forward end of the radius arm.
The forward end of the radius arm is located in a fabricated bracket on the axle and secured through the bushes with
two bolts and nuts. A bush is pressed into the rear of the radius arm which is also located in a fabricated bracket on
each chassis longitudinal and secured through the bush with a bolt and nut.
The radius arms prevent longitudinal movement of the front axle and because of their length allow maximum axle
articulation. The stiffness of the bushes in each radius arm also contributes to the vehicle roll stiffness.
Each radius arm has a notch on its lower edge which provides location for the vehicle jack.
Dampers
Two conventional telescopic dampers are used to control body/axle movement. A turret is located on a bracket welded
to the chassis. The upper spring seat has four studs which pass through holes in the bracket and align with
corresponding holes in the turret. Four nuts are screwed onto the studs and secure the turret and upper spring seat
to the chassis.
A fabricated platform is welded to the axle. The platform has two captive nuts which provide for the attachment of the
damper. A lower spring seat is located on the platform. Each spring seat is handed and has a bracket which secures
the ABS sensor harness and the front brake hose.
Each damper is fitted with a bush at its upper end. The bush locates in the top of the turret and is secured with a cross
bolt. The lower attachment point for the damper is also fitted with a bush. This bush has a spindle through its centre
with a hole at each end. The spindle is seated on the lower spring seat and the axle platform and secured with two
bolts. The coil spring is fitted in a compressed state between the upper and lower spring seats and assists the damper
in controlling the body/axle movement. The upper and lower bushes are replaceable items.
Rubber bump stops are fitted to the chassis above each end of the axle. The bump stops are progressive in their
compression and prevent the axle from contacting the chassis in the event of maximum suspension travel being
reached. The bump stops revert to their original shape once the compression load has been removed from them.
The damper functions by restricting the flow of a hydraulic fluid through internal galleries within the damper body. A
chromium plated rod moves axially within the damper. As the rod moves, its movement is limited by the flow of fluid
through the galleries thus providing damping of undulations in the terrain. The damper rod is sealed at its exit point
from the body to maintain fluid within the unit and prevent the ingress of dirt and moisture. The seal also acts as a
wiper to keep the rod outer diameter clean. A plastic shroud protects the rod and slides over the body as the damper
moves. The coil spring aids the damper to extend after being compressed and also aids the damping process.