Page 441 of 1007
AUTOMATIC GEARBOX - JATCO
44-6 REPAIRS
Gear knob
$% 44.15.07
Remove
Pre 04MY illustrated, (04MY onward similar)
1.Pull gear knob upwards to disengage locating
tang from gear selector lever.
WARNING: Gear knob will be released
suddenly, keep face clear of gear knob
during removal.Refit
1.Position gear knob to gear selector lever
engaging locating tang on knob with slot in
selector lever.
2.Push gear knob fully on to gear selector lever.
CAUTION: Selector lever must be in 'Park'
before fitting knob, failure to comply may
result in damage to selector assembly.
Page 442 of 1007

AUTOMATIC GEARBOX - JATCO
REPAIRS 44-7
Selector cable
$% 44.15.08
Remove
1.Remove front console.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - front - up to 04MY.
2.Release inner cable from selector lever.
3.Remove 'C' clip securing outer cable to selector
housing.
4.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.
5.Remove underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
6.Remove cable tie and release gear selector
cable from clip on body.
7.Loosen selector cable trunnion nut.
8.Release clip securing selector cable to gearbox
bracket, remove selector cable and collect
trunnion from selector lever.Refit
1.Position trunnion to selector lever, locate inner
cable through trunnion, do not tighten nut at this
stage.
2.Position selector cable to gearbox bracket and
secure with clip.
3.Locate cable in selector housing and secure
outer cable in clip.
4.Secure outer cable to selector housing with 'C'
clip.
5.Secure inner cable to selector lever.
6.Fit front console.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - front - up to 04MY.
7.Check and adjust selector cable.
+ AUTOMATIC GEARBOX - JATCO,
ADJUSTMENTS, Selector cable - adjust.
8.Fit underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
9.Remove stands and lower vehicle.
Page 444 of 1007
AUTOMATIC GEARBOX - JATCO
REPAIRS 44-9
Selector indicator - from 04MY
$% 44.15.10
Remove
1.Position gear selector lever in 'Neutral' and
remove gear selector knob.
WARNING: Gear knob will be released
suddenly, keep face clear of gear knob
during removal.
2.Working from forward edge, carefully release
spring clip securing gear selector indicator
assembly to centre console. Release 2
additional clips at the sides and slide assembly
forward.3.Disconnect multiplug from hill descent switch.
4.Disconnect multiplug from gear selector
indicator module.
5.Remove gear selector indicator assembly.
Refit
1.Position gear selector indicator assembly to
centre console.
2.Connect 2 multiplugs.
3.Ensure LED display module is located on pegs.
4.Fit and secure gear selector indicator assembly
to centre console.
5.Fit gear selector knob.
CAUTION: Selector lever must be in 'Park'
before fitting knob, failure to comply may
result in damage to selector assembly.
M44 1992
M44 1993
Page 466 of 1007

AUTOMATIC GEARBOX - JATCO
REPAIRS 44-31
Fluid cooler - KV6
$% 44.24.10
Remove
1.Remove underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
2.Position container to collect fluid spillage.
WARNING: Observe due care when draining
gearbox fluid as the fluid can be very hot.
3.Disconnect 2 fluid cooler hose unions and
discard 'O' rings.
CAUTION: Always fit plugs to open
connections to prevent contamination.
4.Position container to collect coolant spillage.
5.Release 2 clips and disconnect coolant hoses
from fluid cooler.
CAUTION: Always fit plugs to open
connections to prevent contamination.
6.Remove 2 bolts securing fluid cooler.
7.Remove fluid cooler.Refit
1.Position fluid cooler to mounting bracket, fit
bolts and tighten to 25 Nm (18 lbf.ft).
2.Connect coolant hoses and secure with clips.
3.Lubricate new 'O' rings with clean transmission
fluid and fit 'O' rings to fluid cooler hoses.
+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
4.Connect hoses to fluid cooler and tighten
unions to 18 Nm (13 lbf.ft).
5.Refill cooling system.
+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
6.Top-up gearbox fluid level.
+ MAINTENANCE, MAINTENANCE,
Automatic Gearbox – JATCO.
7.Fit underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
Page 467 of 1007

AUTOMATIC GEARBOX - JATCO
44-32 REPAIRS
Hose - fluid cooler
$% 44.24.13
This procedure is identical for both feed and return
hoses.
Remove
1.Remove underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
2.Position container to collect fluid spillage.
WARNING: Observe due care when draining
gearbox fluid as the fluid can be very hot.
3.Disconnect hose from fluid cooler and discard
'O' ring.
CAUTION: Always fit plugs to open
connections to prevent contamination.
4.Loosen union and remove hose from gearbox.
5.Remove and discard 'O' ring.Refit
1.Wipe union and pipe ends using a lint free cloth.
2.Lubricate new 'O' ring with clean transmission
fluid and fit 'O' ring to hose.
+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
3.Position hose to fluid cooler but do not fully
tighten union.
4.Position hose to gearbox and tighten union to
18 Nm (13 lbf.ft).
5.Tighten fluid cooler hose union to 18 Nm (13
lbf.ft).
6.Top-up gearbox fluid level.
+ MAINTENANCE, MAINTENANCE,
Automatic Gearbox – JATCO.
7.Fit underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
8.Remove container.
M44 1639
Page 468 of 1007
DRIVESHAFTS
REPAIRS 47-1
DRIV ESHAFTS REPAIRS
Shaft with both joints - LH
$% 47.10.01
Remove
1.Disconnect battery earth lead.
2.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.
3.Remove road wheel.
4.Remove underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
5.Remove 3 bolts and remove splash shield.
6.Release stake from drive shaft nut.
7.With assistant depressing the brake pedal,
remove and discard the drive shaft nut.8.Remove clip securing brake hose and release
hose from damper bracket.
9.Release ABS sensor harness and brake hose
from damper.
10.Release ABS sensor from hub.
11.Remove 2 bolts securing brake caliper to hub.
Release caliper from hub and tie aside.
CAUTION: Do not allow caliper to hang on
brake hose.
Page 470 of 1007
DRIVESHAFTS
REPAIRS 47-3
Shaft with both joints - RH
$% 47.10.02
Remove
1.Disconnect battery earth lead.
2.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.
3.Remove road wheel.
4.Remove underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
5.Remove 3 bolts securing RH splash shield to
body and remove shield.
6.Release stake from drive shaft nut.
7.With assistant depressing the brake pedal,
remove and discard the drive shaft nut.8.Remove clip securing brake hose and release
hose from damper bracket.
9.Release ABS sensor harness and brake hose
from damper.
10.Release ABS sensor from hub.
11.Remove 2 bolts securing brake caliper to hub.
Release caliper from hub and tie aside.
CAUTION: Do not allow caliper to hang on
brake hose.
Page 472 of 1007

DRIVESHAFTS
REPAIRS 47-5
Gaiter - bell & joint - outer - front
$% 47.10.03
Remove
1.Disconnect battery earth lead.
2.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.
3.Remove road wheel.
4.Remove drive shaft outer joint.
+ DRIVESHAFTS, REPAIRS, Bell &
joint - outer - LH - front.
5.Slide gaiter from shaft.
Refit
1.Clean drive shaft.
2.Fit new gaiter to shaft.
3.Fit drive shaft outer joint.
+ DRIVESHAFTS, REPAIRS, Bell &
joint - outer - LH - front.
4.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
5.Remove stands and lower vehicle.
6.Connect battery earth lead.
Bell & joint - outer - LH - front
$% 47.10.04
Remove
1.Disconnect battery earth lead.
2.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.
3.Remove road wheel.
4.Remove drive shaft.
+ DRIVESHAFTS, REPAIRS, Shaft
with both joints - LH.
5.Place drive shaft in vice.
6.Release both gaiter clips and discard.
7.Slide gaiter along shaft to gain access to outer
joint.
8.Using a drift against the inner part of the joint,
remove joint from shaft.
9.Inspect gaiter for damage and renew if
necessary.
Refit
1.Clean drive shaft and gaiter.
2.Fit new circlip to drive shaft.
3.Position outer joint to shaft, use a screwdriver
to press circlip into its groove and push joint
fully onto shaft.
4.Apply grease from the sachet to the joint.
5.Position gaiter to joint and use a 'Band-it
thriftool' LRT-99-019 to secure the 2 new clips.
6.Fit drive shaft.
+ DRIVESHAFTS, REPAIRS, Shaft
with both joints - LH.
7.Fit front road wheels, fit and tighten nuts to 115
Nm (85 lbf.ft).
8.Remove stands and lower vehicle.
9.Connect battery earth lead.