2002 LAND ROVER DISCOVERY Clutch plate

TRANSFER BOX - LT230SE
DESCRIPTION AND OPERATION 41-9
1Breather pipe, banjo bolt and sealing washers
2Bolt - high/low cross shaft housing and
abutment bracket
3Selector cable abutment bracket
4Multiplug bracket
5Hollow plug
6High/low cross shaft housing
7'O' ring
8High/low cross shaft and lever
9Front output shaft - Differential lock - If fitted
10Dog clutch - Differential lock - If fitted
11Warning lamp switch - Differential lock - If fitted
12Detent plug - Differential lock - If fitted
13Detent spring - Differential lock - If fitted
14Selector shaft - Differential lock - If fitted
15Detent ball - Differential lock - If fitted
16Threaded spacer - Differential lock - If fitted
17Front output housing
18Spring and clips - Differential lock - If fitted
19Bolt - cover plate
20Cover plate21Selector fork - Differential lock - If fitted
22Bolt - front output housing
23Hollow plug
24Circlip
25Front output flange
26Steel washer
27Self-locking nut
28Felt washer
29Oil seal
30Output shaft bearing
31Bearing spacer
32High/low detect switch
33Selector finger and shaft - Differential lock - If
fitted
34'O' rings - Differential lock - If fitted
35Bolt - selector housing - Differential lock - If
fitted
36Selector housing - Differential lock - If fitted
37High/low selector finger
38Front output shaft - Vehicles not fitted with
differential lock

TRANSFER BOX - LT230SE
DESCRIPTION AND OPERATION 41-11
1Breather pipe, banjo bolt and sealing washers
2Bolt - high/low cross shaft housing and
abutment bracket
3Selector cable abutment bracket
4Multiplug bracket
5Hollow plug
6High/low cross shaft housing
7'O' ring
8High/low cross shaft and lever
9Front output shaft - Differential lock - If fitted
10Dog clutch - Differential lock - If fitted
11Warning lamp switch - Differential lock - If fitted
12Detent plug - Differential lock - If fitted
13Detent spring - Differential lock - If fitted
14Selector shaft - Differential lock - If fitted
15Detent ball - Differential lock - If fitted
16Threaded spacer - Differential lock - If fitted
17Front output housing
18Spring and clips - Differential lock - If fitted
19Bolt - cover plate
20Cover plate
21Selector fork - Differential lock - If fitted
22Bolt - front output housing23Aluminium washer
24Warning lamp switch - Differential lock - If fitted
25Circlip
26Front output flange
27Steel washer
28Self-locking nut
29Felt washer
30Oil seal
31Output shaft bearing
32Bearing spacer
33High/low detect switch
34Selector finger and shaft - Differential lock - If
fitted
35'O' rings - Differential lock - If fitted
36Bolt - selector housing - Differential lock - If
fitted
37Selector housing - Differential lock - If fitted
38High/low selector finger
39Front output shaft - Vehicles not fitted with
differential lock
40Washer
41Nut

TRANSFER BOX - LT230SE
DESCRIPTION AND OPERATION 41-15
High/low detect switch
A high/low detect switch is fitted in the front output housing and connects to earth when low is selected. The switch is
connected to the engine ECM, the SLABS ECU and the EAT ECU. The purpose of the switch is to enable selection
of the hill descent feature and to modify the engine fuelling and automatic gearbox gearshift maps stored within the
respective ECM's and ECU's.
Differential lock - Fitted to certain vehicles only
The differential lock selector housing is bolted to the top of the front output housing, the selector finger passes through
the housing, locating in a slot in the differential lock selector shaft. The differential lock selector shaft passes through
the selector fork which is located beneath a plate bolted to the side of the output housing. The selector fork engages
the dog clutch sleeve with the differential rear shaft when the splines of the sleeve and differential rear shaft are
aligned. A spring loaded detent ball fitted in the output housing locates in grooves in the shaft.
Functionality – Vehicles up to 03 model year only
The function of the differential lock used in previous applications is performed on this vehicle by the Electronic Traction
Control System. However, for the purposes of 2 wheel rolling road testing , the differential lock components are
retained. For all driving conditions however, the differential lock must be set in the unlocked position.
Up to 03 model year specification shown
The differential lock must only be engaged for 2 wheel rolling road testing as engagement of the lock disables the
traction control feature and inhibits correct operation of the electronic brake distribution and hill descent features. It
will also be necessary to disconnect the propeller shaft from the transfer box output shaft driving the axle whose
wheels are NOT on the rolling road. The lock may be engaged/disengaged by using a 10 mm open ended spanner
on the flats (arrowed) machined on the differential lock selector shaft.
Vehicles not fitted with a differential lock may be identified by there being no cover or selector shaft (arrowed) on the
front output housing.
WARNING: VEHICLES NOT FITTED WITH A DIFFERENTIAL LOCK MUST NOT BE TESTED ON A ROLLING
ROAD WHERE THE ROLLERS ARE DRIVEN BY THE VEHICLE.

TRANSFER BOX - LT230SE
OVERHAUL 41-55
37.Heat the front output housing to 100°C (210°F)
and fit new output shaft bearing using tool
LRT-41-011.
38.Allow housing to air cool.
39.Fit new bearing retaining circlip ensuring that
circlip is fully seated.
40.Using tool LRT-41-012, fit new output shaft oil
seal. Check that oil seal is just contacting
circlip. 41.Position selected shim in front output housing
and using tool LRT-54-003, fit new differential
front bearing track.
42.Fit bearing spacer to output shaft with chamfer
on spacer towards threaded end.
43. If fitted: Fit dog clutch with flange on clutch
facing towards splined end.
44.Using a copper mallet, drive output shaft into
bearing.
Note: Carry out the following operations for
transfer boxes fitted with differential lock.
45.Compress differential lock selector spring and
fit selector fork.
46.Position selector fork to groove in dog clutch.
47.Fit selector shaft and locate in housing recess,
rotate shaft until the two flats for retaining clips
are at right angles to the cover plate mating
face.

TRANSFER BOX - LT230SE
41-58 OVERHAUL
10.Position tool LRT-51-003 to output shaft drive
flange, remove and discard nut.
11.Remove and discard steel and felt washers.
Remove output shaft drive flange.
12.Using a copper mallet, drive output shaft from
housing.
13.Noting its fitted position, remove bearing
spacer from output shaft.
14.Noting its fitted position, remove dog clutch
from output shaft.
15.Remove and discard oil seal from housing. Reassembly
1.Clean differential lock components.
2.Lubricate components with gearbox oil.
3.Using tool LRT-41-012, fit new output shaft oil
seal.
4.Fit bearing spacer to output shaft with chamfer
on spacer towards threaded end.
5.Fit dog clutch with flange on clutch facing
towards splined end.
6.Using a copper mallet, drive output shaft into
bearing.
7.Compress differential lock selector spring and
fit selector fork.
8.Position selector fork to groove in dog clutch.
9.Fit selector shaft and locate in housing recess,
rotate shaft until the two flats for retaining clips
are at right angles to the cover plate mating
face.
10.Compress selector spring and fit retaining clips
at each end of spring.
CAUTION: Ensure ends of spring are fully
seated in recess in clips.
11.Fit detent ball and spring.
12.Apply Loctite 290 to threads of detent plug.
13.Fit and tighten detent plug, then unscrew 2
complete turns.
14.Fit new 'O' ring to differential lock selector
housing.
15.Fit selector housing, ensure selector finger is
located in shaft recess.
16.Apply Loctite 290 to threads of bolts and tighten
selector housing bolts to 25 Nm (18 lbf.ft).
17.Apply sealant, Part No. STC 3254 to front
output shaft housing.
18.Position housing ensuring that output shaft and
dog clutch splines are correctly engaged.
19.Apply Loctite 290 to threads of bolts.
20.Fit front output shaft housing bolts and tighten
in a diagonal sequence to 45 Nm (33 lbf.ft).

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.

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-8 DESCRIPTION AND OPERATION
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.
Gearbox housing
The gearbox housing contains two epicyclic gear sets on input and output shafts. Hydraulic brake clutches on the
shafts, control which elements of the gear sets are engaged, and their direction of rotation, to produce the P and N
selections, four forward gear ratios and one reverse gear ratio.
Gear ratios
Gear Ratio
1st 2.480 : 1
2nd 1.480 : 1
3rd 1.000 : 1
4th 0.728 : 1
Reverse 2.086 : 1

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-35
Refit
1.Clean oil seal running surfaces.
2.Lubricate oil seal with transmission fluid.
3.Fit new seal into converter housing using tool
LRT-44-001.
4.Fit tool LRT-44-010 to torque converter.
5.Align oil pump drive and fit torque converter to
gearbox.
6.Remove tool LRT-44-010 from torque
converter.
7.Fit torque converter retaining strap.
8.Fit automatic gearbox.
l

+ AUTOMATIC GEARBOX -
ZF4HP22 - 24, REPAIRS, Gearbox -
convertor and transfer gearbox - Diesel.
l

+ AUTOMATIC GEARBOX -
ZF4HP22 - 24, REPAIRS, Gearbox -
convertor and transfer gearbox - V8.
Housing - torque converter
$% 44.17.01
Remove
1.Remove torque converter oil seal.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Torque converter and oil
seal.
2.Remove 18 bolts and plain washers securing
torque converter and intermediate plate to
gearbox casing. Note the position of the 4 bolts
that have sealant applied to the bolt threads
and 6 bolts, (outer ring), which are shorter.
3.Hold input shaft in position and carefully
remove the converter housing and intermediate
plate from gearbox casing.
4.Note the position of the Torrington race on the
forward clutch hub and the thrust washer which
will stay attached to the intermediate plate by
fluid adhesion.
5.Remove and discard intermediate plate gasket.
6.Remove thrust washer from intermediate plate.
7.Separate converter housing from intermediate
plate.
M44 1343
M44 1345