1999 LAND ROVER DISCOVERY maintenance

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.

PROPELLER SHAFTS
DESCRIPTION AND OPERATION 47-3
Front propeller shaft
1Hookes joint
2Grease nipple
3Universal joint4Gaiter/Sliding spline joint
5Lubrication point
The front propeller shaft consists of a tube with a universal joint and a sliding spline joint at the front end, and a
Hookes joint at the rear end. The universal joint is bolted to the pinion flange of the front axle differential. The Hookes
joint is bolted to the front output shaft of the transfer box.
The Hookes joint is lubricated during manufacture and sealed for life. A grease nipple is installed in the universal joint
to lubricate the serviceable, sealed needle bearings of the joint. The sliding spline joint is sealed with a gaiter and
lubricated through a lubrication point on the tube. Because of the proximity of a chassis crossmember to the front
propeller shaft, the lubrication point is normally sealed with a grub screw. During maintenance, the grub screw is
temporarily replaced by a slave grease nipple to lubricate the sliding spline joint.

REAR AXLE
REPAIRS 51-5
REPAIRS
Differential - assembly
$% 51.15.01
Remove
1.Raise rear of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Drain oil from differential.

+ MAINTENANCE, PROCEDURES,
Front and rear axle.
3.If same components are to be refitted,
reference mark propeller shaft and mating
components.
4.Remove 3 nuts and bolts securing flexible
coupling to pinion flange. Release propeller
shaft and tie aside.
5.Using tool LRT-51-008, extract the centralising
peg from the pinion flange. Remove the
centralising peg from the tool.6.Remove LH and RH rear brake discs.

+ BRAKES, REPAIRS, Brake disc -
rear.
7.Disconnect each ABS sensor multiplug.
8.Release each harness from brake hose and
hose bracket.
9.Remove 4 bolts securing each rear wheel hub
to rear axle.
M51 0041B
5
4
M51 0056
LRT-51-008

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

REAR AXLE
51-8 REPAIRS
Refit
1.Clean pinion oil seal recess and pinion flange.
2.Lubricate oil seal lip with clean differential oil.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
3.Using tool LRT-51-010, fit pinion oil seal.
4.Fit pinion flange and securing bolt and washer.
Using tool LRT-51-003 to restrain pinion
flange, tighten pinion flange securing bolt to
100 Nm (74 lbf.ft).
5.Using a tubular drift, fit centralising peg to
pinion flange. Ensure that large diameter part of
centralising peg is below pinion flange
mounting surface.
6.Position propeller shaft and align reference
marks.
7.Fit nuts and bolts securing flexible coupling to
pinion flange and tighten to 76 Nm (55 lbf.ft).
8.Remove stand(s) and lower vehicle.
9.Check differential oil level.

+ MAINTENANCE, PROCEDURES,
Front and rear axle.
M51 0047A
LRT-51-003

FRONT AXLE
REPAIRS 54-5
REPAIRS
Differential - assembly
$% 54.10.01
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.Remove front road wheels.
3.Drain oil from differential.

+ MAINTENANCE, PROCEDURES,
Front and rear axle.
4.If same components to be refitted, reference
mark propeller shaft and mating components.
5.Remove 4 nuts and bolts securing propeller
shaft to differential. Release propeller shaft and
tie aside.
6.Remove LH and RH front brake discs.

+ BRAKES, REPAIRS, Brake disc -
front.7.Disconnect each ABS sensor multiplug.
8.Release each harness from brake hose and
hose bracket.

FRONT AXLE
REPAIRS 54-7
13.Fit front brake discs.

+ BRAKES, REPAIRS, Brake disc -
front.
14.Fit front road wheels and tighten nuts to 140
Nm (103 lbf.ft).
15.Remove stand(s) and lower vehicle.
16.Fill differential with oil.

+ MAINTENANCE, PROCEDURES,
Front and rear axle.
Seal - differential pinion
$% 54.10.20
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.Reference mark front propeller shaft for
reassembly.
3.Remove 4 nuts and bolts securing propeller
shaft to differential. Release propeller shaft and
tie aside.
4.Using LRT-51-003 to restrain pinion flange,
remove bolt and washer securing pinion flange.
Remove pinion flange.
5.Position container to catch oil spillage.