2002 LAND ROVER DISCOVERY brake

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-27
11.Drain transfer gearbox oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
12.Remove front propeller shaft

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
13.Remove rear propeller shaft

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.
14.Remove and discard 3 bolts securing torque
converter to drive plate.
15.Remove handbrake drum retaining screw and
remove brake drum. 16.Remove 4 bolts from handbrake back plate,
release back plate and tie aside.
17.Remove clip securing high/low ratio selector
cable to transfer gearbox lever, remove 'C' clip
and remove outer cable from gearbox.
18.Disconnect 2 Lucars from differential lock
switch and multiplugs from high/low ratio switch
and neutral sensor.
19.Remove cable tie and multi plug from bracket
to transfer box.

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-30 REPAIRS
14.Secure gearbox breather pipes to bulkhead
clip.
15.Connect multiplugs to high/low ratio switch and
neutral sensor. Connect Lucars to differential
lock switch.
16.Position cable tie and multi plug to transfer box
bracket.
17.Connect high/low ratio cable to transfer box
and secure with retaining clips.
18.Position hand brake back plate and tighten
bolts to 75 Nm (55 lbf.ft).
19.Fit hand brake drum and tighten screw.
20.Remove bolts securing tool LRT-99-008A to
gearbox.
21.Rotate engine to align torque converter, fit new
bolts and tighten to 50 Nm (37 lbf.ft).
22.Fit rear propeller shaft.

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

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

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

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
26.Position intermediate silencer and secure to
mounting rubbers.
27.Clean silencer and tail pipe mating faces.
28.Position new gasket to tail pipe and tighten
nuts to 25 Nm (18 lbf.ft).
29.Fit exhaust front pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - Td5, REPAIRS, Pipe - front.
30.Fit bolt securing closing plate to gearbox
housing and tighten to 7 Nm (5.2 lbf.ft).
31.Fit upper bolts securing gearbox housing to
engine and tighten to 50 Nm (37 lbf.ft).
32.Fit starter motor.

+ CHARGING AND STARTING,
REPAIRS, Starter motor - diesel.
33.Tighten remaining gearbox housing to engine
bolts to 50 Nm (37 lbf.ft).
34.Connect battery earth lead.
35.Fit battery cover and secure with fixings.
36.Check and adjust selector cable.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, ADJUSTMENTS, Cable - selector.
Gearbox - convertor and transfer
gearbox - V8
$% 44.20.04.99
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery earth lead.
3.Raise vehicle on a ramp.
4.Remove 8 bolts securing centre cross member
and remove cross member.
5.Remove exhaust front pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Front pipe.
6.Remove 3 nuts securing intermediate silencer
to tail pipe.
7.Release and remove silencer from rubber
mountings.
8.Drain automatic gearbox oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
9.Drain transfer gearbox oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
10.Remove front propeller shaft

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-31
11.Remove rear propeller shaft

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.
12.Remove plug from torque converter housing to
access torque converter bolts.
13.Remove and discard 4 bolts securing torque
converter to drive plate.
14.Remove hand brake drum retaining screw and
remove brake drum.
15.Remove 4 bolts from hand brake back plate,
release back plate and tie aside. 16.Remove retaining clip securing high/low ratio
selector cable to transfer gearbox lever,
remove 'C' clip and remove outer cable from
gearbox.
17.Disconnect 2 Lucars from differential lock
switch and multiplugs from high/low ratio switch
and neutral sensor.
18.Remove cable tie and multiplug from bracket
on transfer gearbox.
19.Release transfer and automatic gearbox
breather pipes from clip at rear of cylinder
block.

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-33
27.Remove 'C' clip securing selector cable to
gearbox bracket.
28.Remove nut securing selector lever to inhibitor
switch and release lever.
29.Disconnect multiplug from inhibitor switch.
30.Loosen gearbox multiplug locking ring and
disconnect plug.
31.Lower gearbox sufficiently to access bell
housing bolts, take care not to trap any pipes or
cables when lowering gearbox.
32.Remove 14 bolts securing gearbox to engine.
33.With assistance remove gearbox from engine.34.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.Position selector lever to inhibitor switch and
tighten nut to 25 Nm (18 lbf.ft).
8.Position selector cable to gearbox and secure
with 'C' clip.
9.Clean oil pipe unions and fit new 'O' rings.
10.Position and tighten pipe unions to gearbox.
11.Position and tighten oil cooler pipe clamps.
12.Position and tighten oil cooler pipe clip to
engine sump.
13.Position engine RH and LH rear mountings
and tighten bolts to 85 Nm (63 lbf.ft) and nuts to
85 Nm (63 lbf.ft).
14.Secure gearbox breather pipes to bulkhead
clip.
15.Connect multiplugs to high/low ratio switch and
neutral sensor. Connect Lucar connectors to
differential lock switch.
16.Position cable tie and multiplug to transfer
gearbox bracket.
17.Connect high/low ratio cable to transfer box
and secure with retaining clips.
18.Position hand brake back plate and tighten
bolts to 75 Nm (55 lbf.ft).
19.Fit hand brake drum and tighten screw.
20.Remove bolts securing tool LRT-99-008A to
gearbox.
21.Rotate engine to align torque converter, fit new
bolts and tighten to 50 Nm (37 lbf.ft).
22.Fit access plug to torque converter housing.
23.Fit rear propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.

PROPELLER SHAFTS
DESCRIPTION AND OPERATION 47-1
PROPELLER SH AFTS DESCRIPTION AND OPERAT ION
Propeller shaft component layout
1Rear axle and brake discs
2Transfer box
3Front axle and brake discs
4Front propeller shaft
5Rear propeller shaft
M47 0237B
1
2
3
4
5

REAR AXLE
DESCRIPTION AND OPERATION 51-3
Wheel hub
Section through wheel hub
1'O' ring
2Hub bearing
3Hub flange
4Wheel stud5Stake nut
6ABS sensor ring
7Drive shaft
8Axle casing
Each wheel hub consists of a hub flange pressed into a hub bearing.
The hub flange is splined to accept the outboard end of the drive shaft, which is secured to the hub flange with a stake
nut. Five studs are installed in the hub flange for the wheel nuts, and a threaded hole is provided for the brake disc
securing screw.
The outer race of the hub bearing is bolted to the end of the axle casing. An 'O' ring seals the joint between the outer
race and the axle casing to prevent leakage of differential lubricating oil. The hub bearing is a sealed unit which
contains twin opposed roller bearings, pre-packed with grease during manufacture. A toothed ABS sensor ring is
integrated into the inner race of the hub bearing. An opening in the outer race of the hub bearing accommodates the
ABS sensor.
Drive shaft
Each drive shaft consists of a solid rod, splined at both ends.

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, clean old RTV sealant
from differential and axle mating faces.
3.Apply RTV sealant to differential or axle mating
face.
4.Apply Loctite 243 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 AND
LUBRICANTS, 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