Page 831 of 1672
AUTOMATIC GEARBOX - ZF4HP22 - 24
44-34 REPAIRS
24.Fit front propeller shaft.
+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
25.Fill transfer gearbox with oil.
+ MAINTENANCE, PROCEDURES,
Transfer box.
26.Fill automatic gearbox with oil.
+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
27.Position intermediate silencer and secure to
mounting rubbers.
28.Clean silencer and tail pipe mating faces.
29.Position new gasket to tail pipe and tighten nuts
to 40 Nm (30 lbf.ft).
30.Fit exhaust front pipe.
+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Front pipe.
31.Position centre cross member, fit bolts and
tighten to 26 Nm (19 lbf.ft).
32.Connect battery earth lead.
33.Fit battery cover and secure fixings.
34.Check and adjust selector cable.
+ AUTOMATIC GEARBOX - ZF4HP22
- 24, ADJUSTMENTS, Cable - selector.
Torque converter and oil seal
$% 44.17.07
Remove
1.Remove 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.
2.Remove retaining strap from torque convertor.
3.Fit tool LRT-44-010 to torque converter and
remove torque converter from gearbox.
4.Remove tool LRT-44-010 from converter.
5.Remove oil seal from converter housing.
Page 838 of 1672
AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-41
Seal - rear extension housing
$% 44.20.18
Remove
1.Remove transfer box
+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - Diesel.
+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - V8.
2.Drain automatic gearbox oil.
+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
3.Remove rear extension housing oil seal from
gearbox.
Refit
1.Clean oil seal recess in gearbox and running
surface on input shaft.
2.Lubricate oil seal running surface with
transmission oil. 3.Using tool LRT-44-001 fit oil seal to extension
housing.
4.Fit transfer box
+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - Diesel.
+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - V8.
5.Fill automatic gearbox with oil.
+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
Page 839 of 1672
AUTOMATIC GEARBOX - ZF4HP22 - 24
44-42 REPAIRS
Gasket - rear extension housing.
$% 44.20.19
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 9 bolts securing rear extension
housing to gearbox case and remove housing.
4.Remove and discard gasket. Reassembly
1.Clean rear extension and mating face.
2.Position new gasket to gearbox case.
3.Position rear extension housing and tighten
bolts to 25 Nm (18 lbf.ft).
4.Fit transfer gearbox.
+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - Diesel.
+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - V8.
5.Fill automatic gearbox with oil.
+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
Page 840 of 1672
AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-43
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.
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).
M44 1109B
97
8
Page 841 of 1672
AUTOMATIC GEARBOX - ZF4HP22 - 24
44-44 REPAIRS
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.
Page 853 of 1672
PROPELLER SHAFTS
47-2 DESCRIPTION AND OPERATION
Description
General
Front and rear propeller shafts transmit the drive from the transfer box to the axles.
On vehicles from 03 model year fitted with the 4.6l V8 engine and 4HP24 transmission, the front propeller shaft is 15
mm (0.6 in) longer and the rear propeller shaft is 15mm (0.6 in) shorter than those used on vehicles with the 4.0l V8
and Td5 engines. This is to accomodate an increase in length of the 4HP24 transmission.
Front propeller shaft
1Hookes joint
2Grease nipple
3Universal joint
4Gaiter/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.
Page 864 of 1672
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
Page 865 of 1672
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
