44 Automatic Gearbox

8/14/2019 44 Automatic Gearbox

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yo;;; 1987 AUTOMATIC GEARBOX

FAULT DIAGNOSIS: ZF4HP22 Automatic Gearbox

Before referring to the fault diagnosis chart, ensure

that the following static checks are carried out first:

INITIAL STATIC CHECKS

Check start positions

Reverse lights

Gear engagements

Full throttle

Oil level

Pressure test

2000 rev/ min

Idle pressure

P & N only

R only

N-D,N-3,N-2,N-l,N-R

Engine switched off, check full travel

at engine and at ped al.

N selected, engine running at normal

running temperature.

1 5 0 k 5 p .s.i.

100 _t 5 p .s.i. at 665 to 735 re v/ m in .

FIT PRESSURE GAUGE

Service tools:

18G502A-0-300 PSI (O-22 kg/cm*)

pressure gauge.

18C502-Flexible hose

LST502-I-Hose adaptor

I. Drive the vehicle onto a suitable hoist.

2. From beneath the vehicle, remove the plug

f r o m t h e b o t t o m o f t h e g e a r b o x , f i t t h e

ad ap tor LST502-1 and tighten sec urely.

3 . F i t t he hose to t he adap to r and t i gh ten

securely.

4. Fi t the ga uge lSG502A to the o ther end o f

t he hose and rou te t o t he i n te r i o r o f t he

vehic le, ensuring that the hose is fastenedclear of any rotating parts and exhaust pipes.

.i

5. Remove the vehicle from the hoist and carry

out road test.

. .Remove the pressure gauge

6. Drive the vehic le onto a sui table hoist and

then reverse instructions 1 to 4.


2/74

l-l44 AUTOMATIC GEARBOX

FAULT DIAGNOSIS-ZF4HP22 AUTOMATIC GEARBOX:

TEST 1SYMPTOM

INTERMITrENT DRIVE

AND HIGH PITCHED

NOISEI

FAULTLOW FLUID LEVEL

O R

RESTRIC TED FILTER

TEST 2

ISELECT D

INO DRIVE

I

SYMPTOMNO DRIVE IN

REVERSEI

D RIV ES ORWARD

ISELECT 1

INO ENG INE BRAKING

CONTINUE

WITH TEST 3

FAULT FAULTREVERSE GEAR C LUTC H BRAKE D

INTERLOCK VA LVE

SEIZED

VEST3

SYMPTOM

NO DRIVE FROM REST

WITH D SELECTED

ISELECT 1

NO DRIVE VEHIC LE DRIVES

FAULTNO 2

FREEWHEEL

CARRY OUT MAIN

INO PRESSURE

NO RMA L PRESSURE FAULT

I C LUTC H ALO W PRESSURE

O RPUMP FAILURE

ORSTIC KING PRIMA RY

REG ULATO R

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Rov;l:1987 AUTOMATIC GEARBOX

TEST 10NO TE:THE DIRECT DRIVE

SYMPTOM. . . CLUTCH WILL-ONLYNONE OR HARSH ENGAGEMENT ENC AGE IF 4TH GEAR IS

OF DIRECT DRIVE CLUTCH ENGAGED SEE SECTION

04 FOR LOCK-UP AND

UNLO C K SPEEDS

APPROPRIATE TO MODEL

YEAR.

C ARRY OUT RO AD TEST PRESSURE

C HEC K WITH G AUG E CO NNECTED

TO TORQUE C ONV ERTER.

. .

PRESSURi NO RMA L PRESSURES C O RRECT

I

BUT REM AIN HIGH

I

FAULT

FAILED DIRECT

DRIVE C LUTC H

FAULTS

POSSIBLE

DlREdT DRIVE C LUTC H HYST:RESIS DIREC T DR;VE C LUTC H

AND TORQUE C ONVERTER VALVE SEIZED CONTROL VALVE SEIZED

C~JNTROL VA LVE SEIZED

TEST 11 NO TE:DIRECT DRIVESYMPTOM - CLUTCH ENGAGEMENT AT

D IREC T D RIV E C LUTC H SHIFT LO W SPEED WILL C AUSE

PO INT INC ORREC T O R A T LO W VlBRATlO N IN THE

SPEED TO RQ UE

I

C ONV ERTER

r

PRESSURE NORMAL

I

FAULTGOVERNOR VALVE

STIC KINGI

DIRECT DRIVE CLUTC H

C ONTROL VA LVE STICKING

CARRY OUT

M AIN LINE AND TORQUE C ONVERTER

PRESSURE CHECK

I

HYSTERESIS

VA LVE STICKING

I

LOW OR INCORRECT

PRESSURE

I

I

DIRECT DRIVE CLUTC H

AND TORQUE

C O NV ERTER

CONTROL VALVE

STIC KING

TEST 12

SYMPTOM

DRIVES IN D IST

BUT IM M EDIA TELY

UPSHIFTS TO 3RD

IFAULT

2ND TO 3RD SHIFT

VALVE SEIZED

REVISED: JULY 88 5


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rot;; 1987 AUTOMATIC GEARBOX

TEST 17SYMPTOM

NO UPSHIFTS AT LIGHT

IGOVERdOR VALVE SHIFT SALVES

STICKING STICKING

SYMPTOMNO ENGINE BRAKING

3 SELECTED 3RD GEAR

IFAULT

CLUTCH C

TEST 19SYMPTOM

DELAYED OR NO DOWNSHIm

OCCURS WHEN MAKING A MANUAL

SELECTION FROM 3 TO 2

IFAULTS

POSSIBLEI 1I

GOVERNOR VALVE

STICKING

2 POSITION 2ND AND 3RD

INTERLOCK VALVE UPSHIFT VA LVE

STICKING STICKING

TEST 20SYMPTOM

AT SPEEDS BELOW 28 MPH

WHEN MAKING A MANUAL SELECTIONFROM 2 TO I , DOWNSHIFT

IS DELAYED OR DOES NOT OCCUR

IFAULTS

POSSIBLE

IGOVERNOR

STICKING

II

1ST TO 2ND

SHIFT VA LVE

I1 POSITION

INTERLOCK VALVE

STICKING

TEST 18

REVISED: JULY 88


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11/74

ROVER AUTOMATIC GEARBOX

.;

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RR524M

.:

1. GEARBOX ASSEMBLY2. INHIBITOR SWITCH ASSEMBLY3. CONTROL UNIT ASSEMBLY

4. FILTER AND SUMP ASSEMBLY

11


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I I44 AUTOMATIC GEARB0.X

RR525M

..:a


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:.:;

1. A CLUTCH ASSEMBLY

2. B CLUTCH ASSEMBLY

:

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,c- RR526M

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RANGt

44 AUTOMATIC GEARBOX ROVER

1. C,C AND D CLUTCH ASSEMBLY

RR527M

1 4


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;;^d;;; 1987 AUTOMATIC GEARBOX 1441

STAGE 1

Inhibitor switch leak elimination

1 .

2.

3.4.5.

6.

7.

Place vehicle on a suitable hoist or over a pit,

open the hood and disconnect the batteryleads.From underneath the vehicle disconnect the

inhibitor lead.Undo and remove the bolt and spring washer.Remove the retaining plate.Using a suitable tool remove the inhibitorswitch from the casing.Fit a new inhibitor switch, retaining plate ifexisting one is damaged, spring washer and

bolt.Reconnect the inhibitor leads.

. . .,. ,.A,..

L. .c.w

Intermediate plate screw plugs leak elimination.

NOTE: The following procedure is for all fourplugs on the plate. Seals that actually leak

should be replaced.

1.

2.

Place the vehicle on a suitable hoist or over apit, open the hood and disconnect the batten/

leads.From underneath the vehicle, using a suitablewrench remove the two hexagon headedplugs situated in the intermediate plate,catching any oil that may leak from the plate.

X4

lkt3. Remove and discard the sealing rings.4. Fit new sealing rings and refit the plugs to the

specified torque.5. Using a suitable hexagon shaped tool, remove

the two hexagon socket plugs, catching anyoil that may leak from the plate.

6. Remove and discard the sealing rings.7. Fit new sealing rings and refit the plugs to the

specified torque.8. Connect the battery.9. Top up the gearbox with the correct oil

through the filler level tube located within theengine bay. (See Section 09).

1 0 . Ensuring the vehicle is on level ground withthe parking brake applied check oil level whileengine is running at idle with neutral selectedafter selecting each gear.

Continued

REVISED: jtJLY88 17


18/74

AUTOMATIC GEARBOX1987 kANClt

ROVER

Selector shaft leak elimination

1. Place vehicle on a hoist or over a pit, open

the hood and disconnect the battery leads.

2. From underneath the vehicle remove the nut

and gear-change lever.

3. Using a suitable tool remove the oil seal.

4. Fit the new oil seal using the selector shaft oil

seal repla cer LST114. For ea se of fitme nt use a

light grease or Petroleum Jelly.

5 . Re f i t gea r -change l eve r , ensu re t ha t i t i s

located correctly.

6. F i t and t ighten nut to the speci f ied torque

(see sec tion 06-Torque values).

Oil pan leak elimination

1. Place vehicle on a suitable hoist or over a pit

open the hood and disconnect battery leads.

2. From underneath the vehicle drain the gearbox

using a suitable container and remove the oil

filler level tube.

3. Remove the six retaining plates and bolts.

4. Remove the sump and discard the gasket.

5. Inspect sump for wear or damage. Replace if

necessary.

6. Fit new gasket onto sump.

7. Refit sump using the six retaining plates and

screws (two straight and four corner plates) to

the spec ified to rque ( see sec tion OC-Torque

values).

RR903M

8. Reconnect oil filler level tube, sump plug with

a new seal to the specified torque (see section

OC-Torque v alue s).

9. Connect the battery leads.

1 0 . Fi l l the gearbox wi th the correct oi l (See

Section 09).

11. Ensuring the vehicle is on level ground with

the parking brake applied check oil level while

engine is running at idle with neutral selected

after selecting ea ch gear.

NOTE: If leak persists and existing oil pan

has been refitted, change the oil pan usingthe same procedure as above.

18, .. , , ,

REVISED: JULY 8b


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I441AUTOMATIC GEARBOX1987 ;-;;;I;

1 2 . Fit the nipple into the cam seat ensuring that

the cam has been turned once before fitment.

This will spring load the cam.

13. Fit the control unit after cleaning the face with

a lint free rag, ensuring the selector shaft

locates into the gear shift fork and fit the

thirteen bolts loosely by hand.

14. Place the selector linkage setting gauge

LST109 in posit ion and gently press the

control unit in the direction as shown and

tighten all thirteen bolts using TX27 Torx bit to

the specified torque (see section 06-Torque

values).

22.

23.

24.

NOTE: T h e kickdown c a b l e m u s t b e

adjusted while the vehicle is running at

idle.

. .

Adjust the cable sheath to achieve a crimp gap

of 0.25 to 1.25 mm (.OlO to .050 in).

Hold the cable sheath while tightening the

locknuts.

Ensuring the vehicle is on level ground with

the parking brake applied, check oil level while

engine is running at idle with neutral selected,

after selecting each gear.

15. Remove setting gauge and fit oil screen using

TX27 Torx bit to the specified torqu e (see

section O6-Torque values).

16. Refit sump with new gasket.

17. Refit the six retaining plates and screws (two

st r a ight and four cor ner p la tes ) to thespecified tor q ue (s ee sec t ion 06-Torque

values).

18. Reconnect oil filler tube and sump plug with a

new seal to the specified torques (see section

06-Torque values).

19. Connect the battery leads.

20. Fill the gearbox with the correct oil (see

Section 09).

21. Connect the kickdown cable to the rear of the

engine.

20

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ro;;; 1987AUTOMATIC GEARBOX 144 1

Extension case leak el imination Oi l Screen

1.

2 .

3 .

4 .

5 .

6 .

7 .

8 .

Rem o ve the t rans fe r box as desc r i be d i n

Section 37.

Using a sui table tool release the four bol ts

from inside the vehicle holding the transfer

gear selector housing and adaptor bracket.From underneath the vehicle using a suitable

t o o l r e l e a s e t h e n i n e b o l t s h o l d i n g t h e

extension housing.

Remove the extension housing and discard the

gasket.

Place extension housing on the bench and

remove the oil seal.

Ensure that a ll the surface s are clea n and the

case is free from damage. if damage has been

found on the case, replace the case.

I f the case has to be rep laced, f i t the two

dowels to the case.

Fit a new gasket and oil seal using the rear oil

seal rep lac er LSTI 08.

9 .

1 0 .

1 1 .

1 2 .

1 3 .

F i t t he ex tens i on case on to t he gea rbox

ensuring the oi l seal is not damaged by the

extension shaft.

Fit and tighten the nine bolts to the specified

torque (see sec tion 06-Torque values).

From inside the vehic le ref i t the four bol ts

which hold the transfer gear selector housing

and ada ptor bracket.

Sec ure the four bolts to the spec if ied torque(see sec tion 06-Torque values).

Refit the transfer box a s de scribed in Sec tion

3 7 .

1 .

2 .

3 .

4 .

5 .

6 .

7 .

8 .

9 .

1 0 .

1 1 .

1 2 .

Place the vehicle on a suitable hoist or over a

pit, open the hood and disconnect the battery

leads.

From underneath the vehicle drain the gearbox

using a suitable container.Discard the sump plug seal ring.

Remo ve the filler/leve l tube from the sump.

Remove the six retaining plates and bolts.

Remove the sump a nd d isca rd the ga sket.

Using TX27 Torx b it und o the three screw s

which hold the oil screen.

Remove the o i l sc reen and d isca rd the 0

rings.

Sep arate the oil sc reen from the suction tube

and discard the 0 ring and oil screen.

Fit two new 0 rings to the o il scree n using a

light grease for ease of assembly.

Fit the suction tube to the oil screen.

F i t t he o i l s c reen to t he con t ro l un i t andsecu re with th ree b olts using TX27 Torx b it

t ighten to the specif ied torque (see section

06-Torque va lues).

RRQOBM

RR6BlM

1 3 .

1 4 .

1 5 .

1 6 .

Refit the sump using a new gasket.

Secure using the six retaining plates and bolts

(two straight and four comer plates), t ightento the spec ified torque (see sec tion 06-Torque

values).

Rec onnec t t he o i l l eve l / f i l le r tube to the

sp ec ifie d t o r q u e ( s e e s e c t i o n 06- To rq ue

values).

Fit sump plug using a new seal to the

sp ec ifie d t o r q u e ( s e e s e c t i o n 06- To rq ue

values).

1 7 . Connect the batter)l leads.

Cont inued

21


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;;d;$ 1987 AUTOMATIC GEARBOX 1441

, . . .

11. Place the selector linkage setting gaugeLST109in position and gently press thecontrol unit against the tool and tighten allthirteen bolts using TX27 Torx bit to thespecified torque (see section 06-Torquevalues).

1 2 .

1 3 .

1 4 .

15.

1 6 .

1 7 .

18.

1 9 .

Remove the setting gauge and fit the oilscreen using TX27 Torx bit to the specifiedtorque (see section 06-Torque values).Refit the sump using a new gasket.Secure with the six retaining plates and bolts(two straight and four corner plates), tightento the specified torque (see section OC-Torquevalues).Reconnect the oil filler/level tube to thespecified torque (see section 06.Torque

values).Fit sump plug using a new seal to thespeci fied torque (see section 06-Torquevalues).Connect the battery leads.Fill the gearbox with the correct oil throughthe filler/level tube located within the enginebay. (See Section 09).Ensuring the vehicle is on level ground withthe parking brake applied, check oil level whileengine is running at idle with neutral selected,after selecting each gear.

Oil Inlet Sealing Rings

1 .

2 .

Place the vehicle on a suitable hoist or over apit, open the hood and disconnect the batteryleads.From underneath the vehicle drain the gearboxusing a suitable container.

RR 9 1 3 M

3. Discard the sump plug seal ring.4. Remove the oil filler/level tube from the sump.5. Remove the six retaining plates and bolts.6. Remove the sump and discard the gasket.7. Using a TX27 Tom bit undo the three bolts

which hold the oil screen.8. Using a TX27 Torx bit undo the remaining

thirteen bolts retaining the control unit and

remove the control unit.9. Clean the surfaces ensuring no damage has

occurred to the mounting face of the case,using a lint-free rag.

10. Using circlip pliers remove the eight circfipsand springs from the gearbox.

11. Using control unit inlet oil sealsremover/replacer LST113 remove the eight oilseals.

12. Clean the orifices and check for damage.

NOTE: If damage has occurred replace thebox as described in Stage II.

Continued


24/74

l-l44 AUTOMAT IC GEARBOX 1987 ro;;;

.: 13.. .*..I:. 14.

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1 5 .

1 6 .

1 7 .

Using the control unit inlet oil seal

remover/replacer LS T1 1 3 fit the new sealsensuring they are seated fully home.Fit the eight compression springs, the fourshort ones at the front and the four long onesat the rear of the box.

Using circlip pliers fit the eight circlips whichretain the compression springs.Fit the control unit ensuring the selector shaftlocates into the gear shift fork and fit thethirteen bolts loosely by hand.

RAS8OM

Place the selector linkage setting gaugeLST109 in position and gently press the

control unit against the tool and tighten allthirteen bolts using TX27 Torx bit to thespecified torque (see section 06-Torquevalues).

1 8 .

1 9 .

2 0 .

2 1 .

2 2 .

2 3 .

2 4 .

2 5 .

Remove the setting gauge and fit the oilscreen using TX27 Torx bit to the specified

torque (see section 06-Torque values).Refit the oil pan using a new gasket.Secure with the six retaining plates and bolts(two straight and four corner plates), tightento the specified torque (see section 06-Torquevalues).Reconnect the oil filler/level tube to thespecified torque (see section OC-Torquevalues).Fit sump plug using a new seal to thespecified torque (see section OCTorquevalues).Connect the battery leads.Fill the gearbox with the correct oil throughthe filler/level tube located within the engine

bay. (See Section 09).Ensuring the vehicle is on level ground with

the parking brake applied, check oil level whileengine is running at idle with neutral selected,after selecting each gear.

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. .

;Giii 1987 AUTOMATIC GEARBOX

GOVERNOR HOUSING

1 .

2.

Rem ove the t rans fe r box as desc r i bed i n

Sec tion 37.

3.

4.

5.

6.

7.

8.

9.

10.

Using a sui table tool release the four bol ts

from inside the vehic le holding the transfer

gear selector housing and adaptor bracket.

From underneath the vehicle using a suitable


extension housing.

Remove the extension housing ensuring that

the sea l i s not damaged and d iscard the

gasket.

Remove the extension shaft and retaining bolt

with 0 ring.

Remove the governor assembly with parking

wheel.

Remove the two screws holding the governor

ho using u sing TX27 To rx bit.

Remove the governor housing complete and

discard.

Inspect the governor hub and parking wheelfor damage, if satisfactory, clean.

Fi t n e w g o v e rn o r h o u si n g c o m p l e t e t o

go vernor hub and pa rking whe el using TX27

Torx bit to the spec ified torq ue (see sec tion

OL-Torq ue va lues).

RR586M

11 . Re f i t t he gove rno r assem b l y w i t h pa rk i ng

wheel onto the output shaf t and push the

assembly till fully seated.

NOTE: To avoid damage to 0 ring use a

light grease or Petroleum Jelly. Ensure the

seal rings are snapped together and are

seated correctly.

12. Fit the extension shaft, apply Loctite 270 to

the retaining bolt and using a new 0 ring,

tighten the bolt to the specif ied torque (see

sec tion 06-Torqu e values).

13. Fit new gasket onto rear of gearbox and fit the

extension housing, taking care not to damage

the seal on assembly.

14. Sec ure th e exten sion ho using u sing t he nine

bo l t s t o t he spec i f i ed t o rque ( see sec t i on

06-Torqu e values).

15. From inside the vehic le ref i t the four bol ts

which retain the transfer gear selector housing

and adaptor bracket.16. Sec ure the fo ur bolts to the sp ec ified torqu e

(see sec tion 06-Torque va lues).

17. Refit the transfer b ox a s de sc rib ed in Sec tion

37.

27


28/74

AUTOMATIC GEARBOX1987 KANGE

ROVER

GOVERNOR HUB

1. Rem ove the t ra ns fer bo x as de scr ibe d in

Section 37.

2. Using a sui table tool release the four bol ts

from inside the vehicle holding the transfer

gear selector housing and adaptor bracket.3. From underneath the vehicle using a suitable


extension housing.

15. F i t the parking wheel to the governor hub

using TX27 Torx b it to the spe c if ied torq ue

(see section 06-Torque values).

16. Fit three new seal ring s onto the F clutc h

hous ing sha f t and f i t 0 r i ng on to ou tp u t

shaft.

NOTE: For ease of fitment of the 0 ringuse a light grease or Petroleum lelly.

4. Remove the extension housing ensuring that 17. Fi t governor assembly and parking wheel onto

the sea l i s not damaged and d iscard the the output shaft and push the assembly til l

gasket. fully seated.

5. Remov e the extension shaft and retaining bolt

with 0 ring and d isca rd 0 ring.

6. Remo ve the g ove rnor assemb ly with parking

wheel.

7. Remove the two screws holding the g overnor


light grease or Petroleum Jelly. Ensure theseal rings are snapped together and areseated correctly.

,:.

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housing using TX27 Torx bit .

8. Using a TX27 Torx b it unscre w the two bo lts

and remove the parking wheel and discard

governor hub.

9. Remove the sec urity c lip and c ounter-weight.

10. Remove the 0 ring from off the output shaft

and discard.

11. Remove the three seal rings from the IF clutch

housing shaft.

18. Fit new gasket onto rear of gearbox and fit the

extension housing taking care not to damage

the seal or assembly.

19. Fit the extension shaft and retaining bolt using

a new 0 ring.

20. Secure the extension housing using the nine

bol ts to the speci f ied torque (see sect ion

06-Torque values).

12. Inspect all parts for damage or wear, replace if

necessary.

13. Fit the counter-weight and security clip into

the new governor hub.

14. Secure governor housing onto governor hub

using TX27 Torx b it to the spec if ied t orq ue

(see sec tion OC- Torque values).

21. From inside the vehicle refi t the four bolts


and a da ptor brac ket. Sec ure the four bolts to

the spec ified to rque ( see section OC-Torque

va lues). Refit the transfer box as described in

Section 37.

28


29/74

I.

..

AUTOMATIC GEARBOX

PARKING PAW1 MECHANISM

1 . Rem ove the t rans fe r box as desc r i bed i n

Section 37.

2. Using a sui table tool , release the four bol ts

from inside the vehic le holding the transfer

gear selector housing and adaptor bracket.

3. From underneath the vehicle, using a suitable

to ol, r e le a se t h e n i n e b o l t s ho ld mg t h e

extension housing.

NOTE: The i l lustrat ion for the following

replacement is located at the top of the

iollowing page.

4. Remove the extension housing ensuring that

the sea l i s not damaged and d iscard the

gasket.

5. Remove the extension shaft and retaining bolt

with 0 ring, disc ard the 0 ring.

6. Remove the governor assembly with parking

wheel.

8.13 _

I O.

1 1 .

1 2 .

1 3 .

1 4 .

1 5 .

1 6 .

1 7 .

1 8 .

1 9 .

2 0 .

NOTE: T a k e c a r e w h e n r e m o v i n g t h e

assembly. Do not damage parts which-could

weaken spring tension.

I nspec t a l l pa r t s f o r wear o r damage and

replace if necessary.

Fit the pin and the leg spring ensuring that the

spring is located correctly.

Fit the pa w1onto the p in and the spring leg

into th e ho le 111the p a wl. This c rea te s te nsion

in the spring.

Fit the p late and gu ide p late using TX27 Torx

b it t o t h e sp e c ifie d t o r q u e ( s e e se c t i o n

O& Torque values).

Re f i t t he gove rno r assem b l y w i t h pa rk i ng

wheel onto the output shaf t and push the

assembly till fully seated.


light grease or Petroleum jelly. Ensure the

seal rings are snapped together and are

seated correctly.

Fit new gasket onto rear of gearbox and fit the

extension housing, taking care not to damage

the seal or assembly.

Fit the extension shaft and retaining bolt using

a new 0 ring.

Sec ure the extension housing using th e n ine

bo l t s t o t he spec i f i ed t o rque ( see sec t i on

06-Torqu e values).

From inside the vehic le ref i t the four bol ts


and adaptor bracket.

Sec ure the four bo lts to the spec ified torqu e

(see Sec tion 06-Torq ue va lues).Refit the transfer box as de sc ribed in Sec tion

3 7 .

7. Rem ove gu ide p late bo lt, using TX27 Torx bit.

8. Remo ve the p late and guide p late from the

gea rbox c ase.

9. Remove the pin, pawl and the spring.

REVISED: IULY 88 2


30/74

AUTOMATIC GEARBOX1987 ANGt

ROVER

STAGE I I

WARNING: Where the use of a transmission

hoist is necessary, it is ABSOLUTELY ESSENTIAL

to follow the hoist manufacturers instruction to

ensure safe and effective use of the equipment.

ZF Gearbox-Remove and refit

Removing

1.

. 2 .

3 .

4 .

5 .

Install the vehicle on a hydraulic hoist.

Open the hood.

Disconnect the b attey lead s.

Release the airflow meter to plenum chamber

hose.

Disconnect the kickdown cable from throttle

linkages located on the throttle lever bracketry

at the rear of the plenum chamber. Remove

the transmission d ipstic k.

Remove the fan cowl from the radiator.

F r om ins ide the v eh i c l e r emov e the fou r

screws securing the glove box l iner to the

glove box and lift out the liner.

Carefully pry the window lift switch panel away

from the front of the glove box. Identify each

switch connection for re-assembly, disconnect

the plugs and remove the switch panel.

Remove the main and transfer gearbox knobs.

6 .

7 .

8 .

9.

10.

NOTE: Refer to Automatic Gear

Selector-Panel Illumination in Section

86.Electrical, page 27, for the r emoval an d

refit of the main gear selector lever.

Carefully pry the centre panel out of the floormoun ted c ons o le and r emov e i t f r om the

vehicle.

11. Release the two bolts and two screws securing

the console assembly to the gearbox tunnel.

12. Release the park ing brake and remove the

co tte r pin, clevis pin and w asher sec uring the

parking brake cable to the parking brake lever.

13.

1 4

1 5

1 6

1 7 .

1 8 .

1 9 .

2 0 .

2 1

2 2

2 3 .

Carefully maneuver the console assembly away

from the radio housing and remove it from the

vehicle.

Release the large nut reta in ing the park ing

brake outer cable to the top of the gearbox

tunnel.

Remove the nut and feed the cable through

the hole in the tunnel to the underside of thevehicle.

Raise the vehicle on the hoist and drain the

gearbox.


removal instructions is located at the top of

the following page.

R e leas e the nu t and c lamp s ec u r i ng the

speedometer cable to the rear of the transfer

box.

Wi thdraw the cab le f rom the speedometer

drive pinion.

Release the cable from the clips at the side of

the gearbox.

Release the four nuts and bolts securing the

rear drive shaft to the rear output flange and

tie the shaft to one side.

Remove the four nuts and bolts securing the

front drive shaft to the front output flange and

tie the shaft to one side.

Release the nuts and bolts securing the front

down-pipes to the front catalysts.

Release the nut at the rear tailpipe bracket,

disconnect the catalysts from the downpipes,

and tie the rear tail pipe and muffler to one

side.

3 0 REVISED: JULY 88


31/74

PO;;; 1989 AUTOMATIC GEARBOX

VRRlQQ5E

24.

25.

26.

27.

Disconnect the oil filler tube from the front ofthe gearbox oil pan.Disconnect the two oil cooler pipes from therear of the gearbox bellhousing.Remove the bolts securing the cross-memberin position, using suitable equipment expandthe chassis and withdraw the cross-member.Remove the front cover from the bottom of

the torque converter housing. Remove oneconverter drive bolt. Mark both the flexibledrive plate and the torque converter to ensurethe unit is reassembled in the original buildposition. Remove the remaining three bolts.

28. Disconnect the inhibitor switch.29. Disconnect the selector linkage.

30. Attach the transmission jack using the adaptorplate (illustration RR739M).

31.

32.

33.

34.

35.

36.

37.

38.

39.

Remove the nuts and bolts holding rearleft-hand side, mounting bracket to chassis.Remove the nuts and bolts holding right-handside mounting bracket to chassis.Lower the jack until the rear brake drum clearsthe rear passenger footwell.Remove the cotter pin and washers securingthe differential lock lever to the connecting

rod, and disconnect the lever from the rod.Disconnect the electrical leads from thedifferential lock switch and neutral warningswitch.Remove the breather pipe from the top of thetransfer gearbox.

Using a suitable floor jack support the rear ofthe engine.Remove the torque converter housing toengine bolts.Carefully withdraw the gearbox and transferbox from the engine takingdamage any seals.

care not to

Continued

.:

REVISED: MAY 89 31


32/74


33/74

Rov;rf.1989 AUTOMATIC GEARBOX

;:._Eliminating Leaks on the Pump Housing

: I._ 1 .

2 .

Remove the gea rbox/ transfer box assemb ly as

previously described.

Place the gearbox on the bench and remove

the torque converter using torque converter

handles 1 8 G1 5 0 1 , taking care not to damagethe co nverter/ oil pump housing oil seal.

3. Remove the twelve hexagonal bolts (inner ring

pattern).

4.

5 .

6 .

Remove bellhousing and pump assemb ly from

gearbox case and discard the gasket.

Remove the eight hexag onal bo lts on the rear

of the pump.

Sc rew in two of the bolts, diagona lly opp osite

each other, tap l ightly using a soft headed

mallet; this will free the pump assembly fromthe intermediate plate.

7 .

8 .

9 .

1 0 .

Remove the shaft seal ing r ing and 0 r ing

from the pump housing and discard.

Using oil seal rep lac er l-ST108 fit the shaft seal

ring into the pump housing.

Fit the 0 ring onto the circumference of the

pump housing.

Align the dowel with its hole in the

intermediate plate a n d p r e ss t he p u m p

housing home.

3 3


34/74

AUTOMATIC GEARBOX 1989 KANCItROVER

11.

1 2 .

1 3 .

14.

1 5 .

1 6 .

1 7 .

1 8 .

Secure the pump housing to the intermediate

p la te us ing the e ight hexagonal bo l ts and

tighten to their specif ied torque (see section

06-Torque values).

Place the bellhousing and intermediate plate

assembly on the bench, front face up. Using

the oi l p ump rotation sleeve LSTI 11, chec kthat the pump gears rotate freely.

Before replacing the intermediate plate and

bellhousing assembly, check that the thrust

washer and axle cage are seated on the A

clutch housing.

Place the gasket and disc washer onto the

beilhousing and intermed iate pla te assemb ly

using a light grease or Petroleum lelly.

f i t b ellhousing and inte rm ed ia te p la te

assem bly o nto gearcase and secure w ith the

t w e l v e h e x a g o n a l b o l t s t i g h t e n e d t o t h e

specified to rq ue ( se e se c t i o n 06-To rque

values).

Place the end f loa t ga uge LSTIII onto the

pump housing and check that the axial play is

between 0.2-0.4 mm (0.008 in to 0.016 in). If

the end f loa t i s excess ive or t igh t , rep lace

existing washer, situated at the rear of the

intermediate plate, with a suitable washer to

give the required end float as stated above.

Re f i t t o rque conve r te r i n to hous i ng us i ng

torque co nverter hand les 18Gl501, che ck ing

that the dimension from the converter f ixing

bolt boss to the converter housing face is 50

mm (1.96 in). If this dimension is achieved the

converter is properly seated in the housing.

Refit the gea rbox/ transfer box a ssemb ly as


Eliminating leaks between gearbox housing and

intermediate plate.

I. Remo ve the ge arbo x/ transfer box assemb ly as


2. Place the gearbox on the bench and remove

the torque converter using torque converterhandles 1t3G1501, taking care not to damage

the c onverter/ oil pump housing-oil seal.

3. Rem ove the 12 hexag ona l bol ts t inner ring

p a t t e r n ) .

4. Remove the bel lhousing intermediate plate

assembly from gearbox case and discard the

gasket.

3 4


35/74

,.I

,.

,..

. . :::.

, :..

,c:.., t: I,*.

: :,..1:

;;^d;;l; 1989 AUTOMATIC GEARBOX

RR5 7 S M

5. Place new gasket onto intermediate plateusing a light grease or Petroleum Jelly.

6. Before replacing the intermediateplate/bellhousingassembly check that thethrust washer and axle cage are seated on theA clutch housing.

7. Fit bellhousinglintermediate plate assemblywith disc washer onto gearcaseand secure

with the hvelve hexagonal bolts tightened tothe specified torque (see section 06-Torquevalues).

8. Place the end-float gauge L S T l l l onto thepump housing and check that the axial play isbetween 0 . 2 - 0 . 4 mm ( 0 . 0 0 8 in to 0 . 0 1 6 in). I fthe end-float is excessive or tight, replaceexisting washer, situated at the rear of ?heintermediate plate, with a suitable washer togive the required end-float as stated above.

9. Refit tclque converter into housing usingtorque converter handles 1 8 G1 5 0 1 , checkingthat the dimension from the converter fixingbolt boss to the converter housing case is 50mm (1.96 in). If this dimension is achieved theconverter is properly seated in the housing.

10. Refit the gearbox/transfer box assembly aspreviously described.

Continued

.i


36/74

-

44 AUTOMATIC GEARBOX 1989 RANGER O V E R,

Replacing Bellhousing

1.

2 .

Remove the gearbox/transfer box assembly as


Place the gearbox on the bench and using the

torque converter handles 18G1501 remove the

torque converter, taking care not to damagethe converter/oil pump housing oil seal.

RR997M

3 .

4 .

5 .

6 .

Remove the eighteen hexagonal bolts.

Remove bellhousing.

Fit new bellhousing.

Sec ure b e l lh o u sin g w i t h th e eighteen

hexagonal bolts to the specif ied torque (see

sec tion 06-Torque va lues).

RR899M

3 6

Refi t the torque converter into the housing

u si n g t o r q u e c o n v e r t e r h a n d l e s 1 8 C1 5 0 1 ,

c hec king that t h e d i m e n si o n f ro m t h e

conver ter f i x ing bo l t boss to the conver ter

housing fa c e is 50 mm (1.96 in). If this

d i m e n s i o n i s a c h i e v e d t h e c o n v e r t e r i s

properly seated in the housing.Refit the gea rbox / t rans fe r assem b l y as


REPLACING PUMP

1. Remove the gearbox/transfer box assembly as


2. Place the gearbox on the bench and remove


handles 18C1501, taking care not to damage

the converter/oil pump housing oil seal.



37/74

PO;;; 1 98 9AUTOMATIC GEARBOX

4 .

5.

6.

Remo ve b ellhousing and pump assemb ly from


Remo ve the eight hexa gona l bolts on the rear

of the pump.

Screw in two of the b olts, diag onally o pp osite

each other, tap l ightly using a soft headed

mallet; this will free the pump assembly fromthe intermediate plate.

RR57BM

1 0 .

1 1

12

5.8

Fit new pump assemb ly al igning the d owel

w i th i ts ho le in the in termedia te p la te and

press the pump housing home.

Sec ure the pump housing to the intermed iate

p la te us ing the e ight hexagonal bo l ts and

tighten to their specif ied torque (see section

06-Torque value s).Place the bellhousing and intermediate plate


the oi l pump rotation sleeve L S T l l l , check

that the pump gears rotate freely.

Remove bellhousing and pump assembly from

gea rbox ca se and disca rd the gasket.

Place the new gasket and disc washer onto

t h e b e l l h o u s i n g a n d i n t e r m e d i a t e p l a t e

assembly using a light grease or Petroleum

Jelly.

Fit bellhousing and intermediate plate

assembly onto gearcase and secure with the

t w e l v e h e x a g o n a l b o l t s t i g h t e n e d t o t h e

specified to rq ue ( se e se c t i o n 06-To rque

values).

.i

Continued

37


38/74

ri44 AUTOMATIC GEARBOX 1989 rUINbtROVER

1 3 .

14.

15.

Place the end-float gauge L S T l l l onto the


between 0.2-0.4 mm (0.008 in to 0.016 in). If

the end-float is excessive or tight, replace

existing washer, situated at the rear of the

intermediate plate, with suitable washer to

give required end-float as stated above.

NOTE: If damage is apparent to the bolts

they should be replaced.

Refit the torque converter into the housing

usin g torq ue convert er handles 18Gl501,

checking t h a t t h e d i m e n s i o n f r o m t h e

converter fixing bolt boss to the converter

housing face is 50 mm (1.96 in). If this

dimension is achieved, the converter is

property seated in the housing.

Refit the gearbox/transfer box assembly as


Replacing Intermediate Plate

1. Remove the gearbox/transfer box assembly as


2. Place the gearbox on the bench, and remove


handles 18C1501, taking care not to damage

the torque converter/oil pump housing oil

seal.

38


pattern).

*

4.

5.

6.


replacement instructions is located at the

top of the following page.

Remove bellhousing and pump assembly from


Remove the eight hexagonal bolts on the rear

of the pump.

Screw in two of the bolts, diagonally opposite

each other, tap lightly using a soft headed

mallet; this will free the pump assembly from

the intermediate plate.

...

RR578M

7. Remove the 0 ring from the pump housing

and discard.

8. Place the bellhousing and intermediate plate

assembly on the bench, front side up.


39/74

7 , 1 6

6 ; 1 7I

9.

10.

1 1 .

1 2 .

1 3 .

1 4 .

1 5 .

1 6 .

1 7 .

1 8 .

1 9 .

Remove the six remaining hexagon bolts and

Secure with six hexagonal bolts (outer ring

remove the bellhousing from the intermediate

plate assembly.

pattern) and tighten to the specified torque

Remove the four screw plugs and seal rings

from the intermediate plate, discard the seal

(see section 06-Torque values).

rings.Remove the oil cooler pipe adaptors and fit

Place intermediate plate and bellhousing

them into the new intermediate plate.

Fit plugs and new seal rings into the new

assembly on bench, front face up.

intermediate plate.

Fit intermediate plate assembly onto the

Fit the 0 ring onto the circumference of the

bellhousing.

pump housing.

Align the dowel with its hole in theintermediate p la te and press the pump

housing home.


plate using the eight hexagonal bolts and

tighten to the specified torque (see section

06-Torque values).

Place the bellhousing and intermediate plate


the oil pump rotation sleeve LS T I 1 1 , check

that the pump gears rotate freely.

20. Before replacing the intermediate plate and

bellhousing assembly check that the thrust

washer and axle cage are seated on the A

clutch housing.

21. Place the gasket and disc washer onto the

bellhousing and intermediate plate assembly

using a light grease or Petroleum Jelly.

22. Fit bel lhousing and intermediate plate

assembly onto gearcase and secure with the

twelve hexagonal bolts t ightened to the

specified torque (see sect ion OC-Torque

values).

23. Place the end-float gauge LSTIII onto the


between 0.2-0.4 mm (0.008 -0.016 in) . I f

end-float is incorrect, replace existing washer,

situated at the rear of the intermediate plate,

with suitable washer to give required end-float

stated above.

24. Refit the torque converter into the housingusin g torq ue convert er handles 18Cl501,

checking t h a t t h e d i m e n s i o n f r o m t h e

converter fixing bolt boss to the converter

housing face is 50 mm (1.96 in). If this

dimension is achieved t he convert e r is

properly seated in the housing.

25. Refit the gearbox/transfer box assembly as


39


40/74

RANGEAUTOMATIC GEARBOX lg8 ROVER

AUTOMATIC GEARBOX-OVERHAUL

1 . Place gearbox into the transmission holding

fixture LS TI I B and tighten.

2.

Remove Torque Converter

NOTE: Refer to Stage II Section for removal

of the gearbox from the vehicle.

NOTE: Care must be taken not to

over-tighten as casing will distort.

Using the torque converter handles 18Gl501

remove the converter from the bell housing.

CAUTION: Ensure no damage occurs to the

pump bush and seal ring lip when removing the

torque converter. The converter is still full of oil

even after the gearbox has been drained, so care

should be taken when removing the unit.

Remove Valve Body

1. Turn the g ea rbox up side d ow n in the fixture.

2. Remove the s ix bol ts and retaining plates

which hold the oil pan.

3. Rem ove the o i l pa n a nd rubb e r sea l and

disc ard sea l.4. Using Torx b it TX27, unsc rew the thre e Torx

headed bolts which hold the oi l screen and

remove . Sep arat e the o i l sc reen from the

suction tube a nd d isca rd the two 0 rings and

oil screen.

_: 40

:


41/74

..:_ I

:

,.I

:

Rd;;; 1 9 8 9AUTOMATIC GEARBOX I44 1

5. Using Torx b it TX27, unscrew the thirte en Torx

headed bolts which retain the valve block to

the ge arbox.

6.

: . Y ,. 7.

Using circlip pliers remove the eight circlips.

Remove the eight springs (four short springs at

the front of the gearbox and four long springs

at the rear of the gearbox).

RRS l l M

8. Remove the eight sealing rubbers using tool

LST113 and d isc ard .

9. Remove the circlip, spring and using the tool

LST113 rem ove the restricto r at t he rea r of the

gearbox.

Remove Parking Pawl and Governor

1.

2.

3.

4.

5.

6.7.

Engage Park position.

Using a suitable wrench unscrew the coupling

shaft bolt and remove the 0 ring.

Remove the coupling shaft.

Remove the nine bolts and washers from the

extension housing.

Remove the extension housing and gasket

from the gearbox and discard the gasket.

Disengage Park position.

Wi thdraw the park ing whee l and governor

hub.

3

RR9 1 BM

. i

Continued

4


42/74

RA NGE

AUTOMATIC GEARBOX * RO V ER

8.

9.

Unscrew the bolt which retains the guide plate

using Torx bit TX27.

Disengage the spring and remove, also the pin

and pawl.

NOTE: T a k e c a r e w h e n r e m o v i n g t h e

assembly. Do not damage parts which couldweaken the spring tension.

RR92tM

1 0 . Using Torx bit TX30 remove the ten Torx bolts

from the rear of casing.

RR53254

4 2, ' ,, : . , . , :, .

Remove inhibitor Switch

LJsinga suitable wrench remove the bolt and

spring washer.

Remove the retaining plate.

Using a suitable tool remove the inhibitor

switch from the casing.Discard switch if damaged.

Remove Bell Housing and Intermediate Plate

I. Using a suitable socket wrench remove the

twelve bolts (inside diameter bolt pattern)

holding the bell housing. ...

.


43/74

$j;;; 1989 AUTOMATIC GEARBOX

, . . 2.

3.

Remove the be l l hous ing and in termedia te

p la te assembly comple te , and d iscard the

gasket.

Remove the thrust washer, axle bearing and

disc washer from the input shaft.

NOTE: Under nor mal vorking c ondit ions

t h e r e i s n o n e e d t o s e p a r a t e t h e b e l l

h o u s i n g f r o m t h e i n t e r m e d i a t e p l a t e

assembly. If damage has occurred to either

the bell housing or intermediate plate see

the appropriate section.

Remove A Clutch Assembly

1 . Turn gea rbox with front fa c ing upw ard s.

2. Remove input shaft and A c lutch assembly

from gearbox.

m

3. Remove inner carrier A, disc, axial bearing and

thrust washer.

Remove B Clutch Assembly

I. Using tw o suita ble sc rewd rivers remo ve the

small snap ring in cylinder 6.

2 . Us ing the B c lu tch assembly pu l le r hooks

LSTllS remo ve the B clutch a ssemb ly.

NOTE: To remove assembly, lift up cylinder

B until it stops, push agsembly back downand lift up again using more weight.

Continued

43


44/74


45/74

.

. ,.: .

Ro v;l:1989 AUTOMATIC GEARBOX I44 1

Transmission Gear Selector Assembly and

Kickdown Cable

Remove and overhaul

1.

2 .

3 .

4.

5 .

6 .

7 .

Remove the kickdown cable from the cam.

U s i n g kickdown ca b l e r e m o v e r LST112,remove the kickdown cable from the casing.

Using a punch remove the roll pin from the

selector shaft.

Using a pair of pliers or grips pull the selector

shaft from the casing.

Remove the stop washer, connection rod, cam

and leg spring.

Using a screwdriver pry out the seal ring

located in the gearbox casing and discard.

NOTE: At this stage the gearbox is totally

stripped.

Inspect and clean casing ensuring no damage

has occurred.

RR 9 1 5 M

Assemble

8. Fit new seal ring into gearbox casing using

selector shaft oil seal replacer LST114.

9 .

1 0 .

1 1 .

1 2 .

1 3 .

1 4

? 8

Fit connection rod into the stop washer.

Place stop washer with connection rod into

the gearbox casing and then feed the selector

shaft into the casing.

Fit the leg spring onto the cam.

Place the assembly into the gearbox casing

and push the selector shaft through until thehole in the shaft aligns with the hole in the

stop washer.

Using a suitable punch, fit roll pin with the

open side facing the rear of the gearbox

casing.

Fit new kickdown cable assembly into its seat

on the gearbox casing.

RR540M

.i

15. Fit the nipple of the kickdown cable into the

cam seat ensuring the cam has been turned

one revolution to load the spring.

NOTE: Af ter gearbox has been ref i t ted

check the kickdown cable and gear selector

adju stmen ts are cor rect . (S ee kickdown

cable adjustment and gear lever selector

cable setting).

REVISED: DEC. 87 4 5


46/74

rl KANtit44 AUTOMATIC GEARBOX lg8 ROVER

Fit Inhibitor Switch

1.

2.

F i t new inhibi tor swi tch i f exist ing one was

damaged.

Rep lac e retaining pla te and f ix wi th spr ing

washer and bolt, securing tightly.

4th Gear Assembly Overhaul

1. Using soft- jawed vice secure the 4th gear

assembly by gripping the output shaft.

2. Remove the sungear.

3. Remove the pla net ge ar assemb ly.

NOTE: Removal of snap-ring on assembly isnot necessary unless damage has occurred.

4. Remo ve the d isc w asher, axia l bea ring and

thrust washer.

5 . Rem o ve a ssem b l y f rom the v i c e a nd tu rn

upside down onto the bench.

6. Remo ve c ylinde r F from c ylinde r E.

7. Remove cylinder E from the freewheel 3rd.

8 . Rem ov e ax i a l d i sc , c ag e and two th rust

washers.

46 REVISED: DEC. 87

9. Using pl iers a n d sc r e wd ri ve r re m o v e the

snap-ring on carrier E.

10

11.

12.

13.

14.

15.

16.

Turn the assemb ly around and remove the

output shaft f rom r ing gear by pushing the

gear downwards.

NOTE: Do not remove the snap-ring on

output shaft.

Place ring gear on bench, teeth side down.

Remo ve c arrier E from the ring ge ar assemb ly.

Remove the freewheel cage assembly from the

ring gear by using an upward turning motion.

Remove the snap-ring retaining the freewheel

ring (inner) to the hollow gear.

Remove the freewheel ring (inner) from the

hollow gear.

Remo ve freewhee l cag e from freewhee l ring

(outer).

NOTE: Care should be taken whenremoving the freewheel ring, which due tothe rollers and springs becoming loose mayfall out.

..,


47/74

:.:.,::

Rov;l;1989 AUTOMATIC GEARBOX

17. Remove the snap-r ing reta in ing the c lutch

pla tes and steel plate s in cylind er F.

18. Remove four clutch plates and five steel plates

from cylinder F.

19. Usin g c lu tc h sp rin g c o m p re ssor LST1016-I,

press down on the spring plate and remove

the split rings.

IRR543M

I

20. Remove the spring plate.

21 . Turn the c y l ind er ups ide d own, us ing twosmall punches placed in the holes

(d iametr ica l ly oppos i te each o ther ) , push

down and remove the piston.

22. Remo ve a nd d isca rd the two 0 r ings from

the piston.

NOTE: The five sealing rings do not need tobe removed on the cylinder unless anydamage has occurred to them.

23. Remove the snap ring from cylinder E.

24. Remove the four clutch plates and five steel

pla tes from c ylinde r E.

25 . Us ing c lu tch spr ing compressor LS T 1 0 1 6 - 1 ,

press down on the spring plate and remove

the split rings.

26. Remove the pressure plate.

27. Remove piston E by using air pressure directed

into the oil feed hole.

28. Remo ve a nd d isca rd the two 0 r ings from

the piston.

WARNING: Before using an air line ensure allnecessary safety precautions are taken to

prevent personal injury, i.e., safety glasses,

protective clothing etc.

NOTE: Do not remove the snap-ring at thebottom of the E cylinder, unless damaged.

Continued


48/74

RANGE

AUTOMATIC GEARBOX lgag ROVER

YI

,_.. . . . . .

:I

. -48

.


49/74

48,49,52,54,55 43

36,38,43,55,56,- 35-41

/

~~~ \

NJ,41 37,38 30 29,y. 34,35,57

0

:


50/74

AUTOMATIC GEARBOX1989 KANGt

ROVER

Assemble

29. Fit three seal rings on the outside hub andtwo seal rings on inside hub of cylinder F if

they have been removed.

4 0 .

4 1 .

4 2 .

NOTE: Ensure each seal ring is snappedtogether.

3 0 . Fit new 0 rings onto the F piston. 4 3 .

NOTE: For ease of assembly applyPetroleum jelly on 0 rings and stretch the

i n n e r 0 r i n g to a v o i d d a m a g e o n

installation.

3 1 .

3 2 .

3 3 .

Fit p iston F into c ylind er F.

Fit spring plate using clutch spring compressor

LST116-1. 4 4 .

Fit the two halves of the split ring to secure

the spring plate in position, then remove the

clutch spring co mpressor.

Install the clutch plates and steel plates into

the F cylinder starting with a steel plate then

clutch plate finishing up with the end plate

which is thicker than the normal steel plates.

Fit the snap-ring into cylinder F to retain the

clutch plate assembly.

4 5 .

4 6 .

3 4 .

4 7 .

3 5 .

4 8 .

49.

5 0 .

NOTE: Do not confuse the steel plates of Fclutch with that of the E clutch. Thedifferences are thus: F clutch-steel plates

are thicker and the end plate has no innerteeth.

3 6 .

3 7 .

Fit new snap- ring at bo ttom o f cylind er E if it

has been removed.

Fit the two 0 rings onto the E piston.

NOTE: For e a s e o f assembly applyPetroleum Jelly.

3 8 .

39.Fit E piston into cylinder E.

Fit the pressure plate with depression facing

downwards.

50

RR545M

5 0

Fit spring plate using clutch spring com pressor

LSTl016- 1.

Fit the two halves of the split ring to secure

the spring plate in position then remove the

clutch spring compressor.

Insta l l the c lutch plates and steel p lates,

starting with a steel plate then clutch plate,

finishing up with the end plate which is thicker

than the normal steel plates.

Fit the snap- ring into c ylinde r E to retain the

clutch plate assembly.

NOTE: Do not confuse the steel plates of E

clutch with that of the F clutch. The

differences are thus: E clutch-steel plates

are thinner and the end plate has inner

teeth.

Fit the freewheel r ing ( inner) to the hol low

gear.

Secure using the snap-ring.

Fi t f reewheel cage into the freewheel r ing

(outer), and press home.

Turn the freewheel c ag e in the freewhe el ring

(outer) until rim of the cage has been seated.

Fit ca rrier E to freewhe el c ag e assembly.

Fi t f reewheel cage assembly to r ing gear

assembly using a clockwise motion.

A minimum clearance of 0.1 mm (0.0039 in)

shou ld be ob ta ined be tween the f reewhee l

cage assembly and ring gear.

.,. %,

j

. . . . .

1

,:


51/74

rot;; 1989AUTOMATIC GEARBOX

.( .: _.I.:. . . .

5 1 .

5 2 .

5 3 .

5 4 .

Inspect the output shaft for damage to the

snap -ring , if a ny, re pla c e sna p- ring ; also

remove 0 ring and discard, replace with new

0 ring.

Align inner teeth of carrier E with freewheel

ring (inner) teeth and then place freewheel 3rd

assembly onto the output shaft.

Sec ure snap-ring into posit ion, retaining the

freewheel 3rd.

F i t t he s tee l t h rus t washe r and then the

copper thrust washer onto the freewheel 3rd

assembly.

5 5 .

: , :. .*

5 6 .

5 7 .

Fi t cy l inder E onto f reewheel 3rd assembly

using a turning motion, ensuring that the teeth

of the end plate l ine up with the freewheel

ring touter).

NOTE: When correctly assembled, copperthrust washer must be touching cylinder E

assembly. The cylinder E assembly will turnin a clockwise direction when holding theoutput shaft. If the cylinder E assembly isturned in a counter clockwise direction thefreewheel will lock up.

Fit the a xial ca ge and a xial disc onto the rear

of cylinder E.

Using a turning motion, fit cylinder F assembly

onto c ylinder E assemb ly.

58. When correctly mounted the raised edge of

the output shaft will be 10.00 mm (0.393 in)

above the top surface of cylinder F assembly.

NOTE: Disengagement of end plate andfreewheel ring (inner) will occur if end playexceeds 3.00 mm ( 0 . 1 1 8 in).

RR546M/I

59.

6 0 .

6 1 .

6 2 .

6 3 .

6 4 .

6 5 .

Fit the complete 4th gear assembly into the

gearbox, ensuring that the oi l feed holes in

cy l i nde r F l i ne up w i t h t he co r respond i ng

holes in the gearbox casing.

Secure the 4th gear assembly to the gearbox

using ten c ounte rsunk screw s. Tighte n sc rews

to the spe ci f ied torque using Torx b i t TX30

(see sec tion 06-Torque values).

NOTE: If screws are not tightened correctly,clutch pressure will be lost in clutch F.

Turn the ge arbo x so that the front of the c ase

is uppermost. .i

F i t the d isc washer , ax ia l cage and thrus t

washer onto the 4th gear assembly.

Fit the seal ring onto the planetary case and

snap together if ring has been removed.

Fit the planetary set into the hollow gear using

a turning motion.

Fit the sun gear onto the planetary set.

Continued

51


52/74

r-144 AUTOMATIC GEARBOX

Refit park mechanism Brakes C, C and D with planetary sets-overhaul

1. Turn gearbox into a horizontal p osition.

2. Fit leg spring over pin and place into rear of

. gearbox.

3. Fit paw1onto pin, to tension spring fit leg of

spring into hole of pawl.4 . Fi t p l a te and gu ide p la te and t i gh ten to

sp ec i f ied to rque using Torx b i t TX27 (see

sec tion 06-Torque va lues).

5. Turn gea rbox so t hat the front of t he c ase is

uppermost.

6. Fit the disc and axial cage.

1 .

2 .

3 .

4 .

5 .

6 .

7 .

0 .

9 .

1 0 .

1 1 .

1 2 .

1 3 .

1 4

1 5

Remove the centre plate assembly.

Remove the two brake C clutches and two

steel plates from cylinder C-D.

Remove freewheel 2nd complete.

Remove the two brake C clutches and three

steel plates from cylinder C-D.

R e m o v e t h e c y l i n d e r C - D w i t h b r a k e D

assembly.

Remove the support ring from the planetary

sets assem bly.

Remove the front planetary set with freewheel

assembly.

Remove the sunsha ft from the a ssembly.

NOTE: Do not remove the seai ring from

the sunshaft unless damaged.

Remove the snap-ring from the hollow gear.

Remove the hollow gear from the assembly.

Remove the rear planetary set.

Remove the thrust washer and axial bearing.

Remove the intermediate shaft with the hollow

gear complete.

R emov e the ax ia l bea r i ng and tw o th r us t

washers, one from each side of the bearing.

Remove the distance ring.

NOTE: The snap-ring in the webshaft need

only be removed if damaged.

.i

5 2

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KANGti

AUTOMATIC GEARBOX * ROVER

23. For ease of removal of both piston C and

piston D, use air pressure fed through the oil

feed holes.

WARNING: Before using an air line ensure ail

necessary safety precautions are taken to

prevent personal injury, i.e., glasses, protectiveclothing etc.

24. Disca rd 0 rings from b oth piston assem blies.

25. Using the clutch spring compressor remove

the spring plate, as previously explained, from

the centre plate assembly.

26. To rem ove the piston use a ir pressure aspreviously described and discard 0 rings.

Assemble

27.

2 8 .

2 9 .

3 0 .

3 1 .

3 2 .

3 3 .

3 4 .

3 5 .

3 6 .

3 7 .

3 8 .

Sec ure the w eb sha ft into a soft-jawed vice.

Fit the snap-ring if it has been removed into

the lower groove.

Fit the distance ring into the webshaft.

Place a disc washer and axial cage into theassembly.

Assemble together the hollow gear with the

intermediate shaft and secure w i t h t h e

snap-ring.

Place the other disc washer onto the rear of

the intermediate shaft using grease.

Fit the intermedrate shaft assembly Into the

webshaft ensuring the disc washer mates up

to the axial cage.

Using a turning motion fit the rear planetary

set Into the hollow gear.

Fi t the f ront ho l low ge ar in to t he webshaft

assembly and secure with a snap-ring.

insert disc washer and axial cage.

Plac e su pp o rt ring o n t o t h e websha ft

assembly.

Tap the two fitt ing p egs down into the slotson the side of the cylinder C-D if they have

been removed.

3 9 . Place the two 0 rings onto piston D.

NOTE: For ease of assembly, applyPetroleum jelly to the 0 rings.

37

/

29 2fJ 27.33

I

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KANGEAUTOMATIC GEARBOX lg8 ROVER

.

5 3 .

5 4 .

Fit end plate which has three groups of three

teeth, of which the middle tooth must fit into

!he short slots in the C-D cylinder.

F i t the C c lu tch assembly s tar t ing w i th a

clutch plate ending with a steel plate.

NOTE: When fitting these plates ensureteeth on the outside do not go into the Vshaped area of the C-D cylinder.

If thin steel plates have to be added into

the C or C clutch assembly ensure that

these plates are placed on the side nearer

to the respective pistons.

5 7

I 5 5 I I

5 5 . Fit the two 0 rings onto the p iston C.

NOTE: For ease of assembly, use PetroleumJelly.

5 6 .5 7 .

5 8 .

5 9 .

6 0 .

6 1 .

Fit C piston assembly into centre plate.Using c lutch spring c om pressor LSTl016-I, fit

spring plate and the two i~alves of the spl i t

rings.

Place the centre plate onto the C-D cylinder

making sure that the ' V' shape in the plate

locates in the V shaped hollow in the C-D

cylinder.

Remove the C, C and D c lutch a ssemb ly from

vice and place a greased thrust washer to the

rear face of the webshaft.

Fit the whole assembly into the transmission

case using the gear train remover/replacer

LST717, ensuring th at the oil fee d ho les are

a l i g n e d w i t h t h o s e i n t h e b o t t o m o f t h e

casing.Sec ure the whole assemb ly with a snap -ring

which fits into the groove inside the casing.

5 6

iS

6 0


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I I44 AUTOMATIC GEARBOX

9,lO

RR559M

i

58.:


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Al,JTOMATlC GEARBOX

A Clutch Assembly Overhaul

1 . Re m o v e t h e i n p u t s h a f t b y h o l d i n g t h e A

clutch assembly firmly and pushing the shaft

against the working surface. Remove the 0

ring and discard.

2. Using a suitable press, depress the A-B carrier

and remove the snap-ring.3. Remove carrier A-B.

4. Remove the six clutch plates and seven steel

plates, plus two wavy spring plates fitted to

later transmissions.

NOTE: If there is evidence of clutch slip or

if the plates are worn, replace the clutch

unit using the latest type.

5. Remove spring plate.

6. For ease of removal of piston A, use air

pressure fed through the oil feed hole.

WARNING: Before using an air line ensure all

necessary safety precautions a r e t a k e n t o

prevent personal injury, i .e. , safety glasses,

protective clothing etc.

RR5 6 1 M \/

7. Remove and disca rd both 0 r ings on piston

A.

REVISED: DEC. 88

Continued


60/74

1441AUTOMATIC GEARBOX1989 r;;;r;

..

Assemble 1 6 . Fit the thrust washer onto the input shaft seat.

8. Fit the two 0 rings onto piston A.

9. Pidce the piston into cylinder A.

10. Fit the spring plate into the cylinder A with the

convex side facing the piston.

11. Placing carrier A-B on the bench, fit the clutchunit. If the latest clutch unit is being fitted, see

RR2669E for the correct build sequence. Note

a l so t ha t one s tee l p l a te i s o f a l t e rna t i ve

thic kne ss.

NOTE: Use Petroleum Jelly to retain washer

in place.

17. Install the inner carrier A onto the intermediate

shaft within the gearbox.18. Place the disc washer and axial cage into the

inner ca rrier A.

12. Fit carrier A-B with the clutch assembly onto

cylinder A.

19. Fit cylinder A assembly into the gearbox using

a righ t to left tw isting m otion. This will ena ble

the teeth of the clutch plates to mesh into the

A-B carrier and inner carrier.

13. Using a suitable press, depress the A-B carrier

and secure with the snap-ring.

14. Fit the two seal rings, if removed, and an 0

ring onto the input shaft.

15. Fit the input shaft into the cylinder A assembly

and press downwards unt i l shaft meets the

stop.

L .

FRIC TIO N

A RZ669E

RR562M

6 0

1

REVISED: DEC. 88


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. .. :.y$,

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._d

R;;; 1987AUTOMATIC GEARBOX

NOTE: When properly engaged the top of

the cylinder A should not protrude more

than 8.5 mm (0.33 in) above the gearbox

front face.

4.

20. Place the thrust washer and axial cage onto

the A cylinder.5.

Pump, Intermediate Plate and Bell Housing

Remove the six remaining bolts situated on

the inside of the bell housing.

Separate the b e l l h ou si n g from the

intermediate plate.

Pump Assembly

Remove and Overhaul6.

Place the bell housing on the bench, open

face down.

Remove the eight hexagonal bolts on the rear

of the pump.

Screw in two b olts, diago nally opp osite eac h

other, tap l ightly using a soft-headed mallet,th is wi l l f ree the pump assembly f rom the

intermediate plate.

7.

8.

Using a suitable tool remove the shaft sealing

ring a nd 0 ring from the pump housing and

discard.

Strip, inspec t and clea n the p ump assemb ly

using a lint-free rag.

N O T E : I f d a m a g e h a s o c c u r r e d t o t h e

assembly, replace the whole pump.

Replac e the pump hollow gear and pump ge ar

into pump housing with the marked side of

gears facing upwards.

Continued

61


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AUTOMATIC GEARBOX

RR568M

Refit bell housing, intermediate plate

assembly

1 7 . Inspect and clean the bell housing.

1 8 .

1 9 .

2 0 .

2 1 .

2 2 .

2 3 .

2 4 .

and pump

NOTE: If damage is found replace the bell

housing

Align the dowel in the pump with its hole in

the intermediate plate and press the housing

into position.


plate with the eight hexagonal bolts and

tighten to the specified torque (see section

06-Torque values).

Using the oil pump rotation sleeve LSTlll

check that the pump gears rotate freely.Place the gasket and disc washer onto the

intermediate plate assembly using a petroleum

jelly.

Fit the intermediate plate onto the gearbox.

Fit the bell housing onto the intermediate

plate assembly.

Secure with the six short bolts which locate

on the outside diameter ring pattern within

the bell housing and the twelve long bolts

which are located in the inner diameter ring

pattern. Tighten all the bolts to the specified

torque (see section 06-Torque values).

Continued

REVISED: DEC. 87 63


64/74

,

2 4

RR570M

25. Using the end-float gauge LSTlll check the

axial clearance 0.2 to 0.4 mm (0.008 to 0.016

in). If the axial clearance is not achieved,remove the bell housing/intermediate plate

assembly complete and replace existing disc

washer us ing a thicker or th inner one

depending on the reading f i rs t taken.

Re-assemble bell housing/intermediate plate

and check the axial clearance once again.

Repeat this operation until axial clearance has

been achieved.

Checking Axial Clearance

1. Fit LSTlll end-float gauge onto the output

shaft, making sure the outer shaft engages

into the pump.

2. Pressing the output shaft towards the rear of

the gearbox and tighten the three screws on

the gauge.

3. Measure the clearance and note.

4. Now secure the remaining screw which retains

the outer shaft to the inner collar.

5. Pull the whole assembly away from the bell

housing, measure the clearance and note.

6. Subtract the first measurement from the

second to obtain the axial clearance.

Extension Housing and Governor-Overhaul

1. Remove the two bolts using Torx bit TX27retaining the parking wheel.

2. Remove the clip and counterweight from

inside the governor hub.

3. Remove the two bolts from the top of the

governor hub which releases the housing and

discard.

4. Release the retaining clip and discard.

5. Remove the pin, spring, piston and weight

from the governor housing.

6. Clean and inspect all parts for damage.

NOTE: Replace any par t which may be

damaged.

7. Remove the seal ring from the extension

housing.

8. Clean and inspect the extension housing for

damage.

NOTE: If the dowels are damaged replace

the dowels only . I f extension casing is

damaged replace the case and dowels.

9. Inspect and clean extension- shaft and bolt for

damage, replace if necessary.

REVISED: DEC. 87

,

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l-l44 AUTOMATIC GEARBOX 1989 HANbtROVER

RR2 5 6 2 E

A: Centre of the li ft ing hoist

x: Drill fixing holes to suit hoist table

Material: Steel plate BS 1449 Grade 4 or 1 4 (Mild Steel).

ADDITION: sEPT. 88


71/74

PO;:; 1989 AUTOMATIC GEARBOX

ZF MAIN GEARBOX AND BORG WARNER

TRANSFER GEARBOX

Remove and refit

Preparation - under bonnet

WARNING: Where the use of a transmission

hoist is necessary, it is ABSOLUTELY ESSENTIAL

to follow the hoist manufacturers instructions to

ensure safe and effective use of the equipment.

1. Place the vehicle on a hydraulic hoist andchock the road wheels.

2. Disconnect the battery negative terminal.3. Release and remove the fan blade assembly.

Note the assembly has a left hand thread.

4. Release the clamp and remove the air intakehose from the neck of the plenum chamber.

5. Disconnect the kickdown cable from the

throttle linkage.6. Release the two gearbox breather pipes fromthe clip located on the lifting eye at the rearof the right hand cylinder head.

7. Remove the gearbox dipstick.

Inside the vehicle

. 8. Select low range, unscrew and remove the

transfer gearbox knob.9. Unclip the top cover of the main gearbox

selector and remove the circlip, withdraw thedetent button. Remove the circlip above theselector knob retention nut, remove the nut,serrated washer and withdraw the selector

knob.10. Carefully pry the inset panel out of the floor

mounted console, complete with gear selectorillumination panel and ashtray. Disconnect theelectrical multi - plug to the graphics panel,and remove the inset panel.

11. Release the four screws and remove the glovebox liner.

12. Carefully pry the window lift switch panel fromthe front of the glove box. Push the panelcomplete with switches back through thepanel opening and place on the gearboxtunnel.

RR2578M

13 Release the two bolts and two screws securingthe glove box/console assembly to thegearbox tunnel.

14. Detach the two relays from the inner side of

the glove box.15. Disconnect the electrical leads to the rear

cigar lighter.

16. Disconnect the parkbrake cable from theparkbrake lever. Raise the lever ;+J~zsimultaneously detaching thebox/console assembly from the lower dash.Remove the assembly from the vehicle.

17. Remove the retaining clip and pull theparkbrake adjustment thumb wheel from theouter sleeve. Push the inner sleeve to theunderside of the vehicle.

18. Remove the sound deadening trim from thetop of the gearbox tunnel.

19. Remove the screws and detach the retainingplate from around the transfer gearbox lever.

Continued

ADDITION: SEPT. 8871


72/74


73/74

R$;i 19 89 AUTOMATIC GEARBOX

.I

34.

,, :

35.

36.

Rotate the engine using the crankshaft pulley

unti l two of the access holes in the dr ive

plate/ ring g ear assemb ly are visible through the

bell housing bottom cover opening.

Remove the two bolts that are visible through

the access holes, which secure the drive plate

to the to r que c onv e r te r . Ma r k one o f theaccess holes and a bolt hole in the converter

with an identification line to aid re - assembly

and to maintain original build setting.

Rotate the crankshaft 180 until the remaining

access holes are visible. Remove the remaining

two bolts.

RR2544E

I

;, .(

._..:,

,, .: ; 1

:. ., 1.

37. Position a suitable transmission floor jack on

the rear output housing or brake drum to

su p p o r t t h e w e i g h t o f t h e t r a n s m i ssi o n

assembly.

38. Remove the bolts and withdraw the transfer

gearbox mountings.39. Fit the previously manufactured fixture on a

transmission hoist, raise the hoist and position

t h e f i x t u r e a n d h o i s t u n d e r t h e t r a n s f e r

gearbox mounting points.

40 . Using the or ig ina l ge arbo x mounting bo l ts

secure the fixture to the gearbox.

41. Remove the transmission floor jack from the

rear of the transfer gearbox.

42. Carefully lower the transmission until the top

o f t h e t r a n s f e r g e a r b o x c l e a r s t h e r e a r

passenger footwell.

43. Position the transmission floor jack under the

e n g i n e t o s u p p o r t t h e w e i g h t w h i l e t h e

bellhousing bolts are removed.

44.

45.

Remove the bellhousing bolts noting that one

of the bolts also secures the gearbox dipstick

tube.

Withdraw the transmission assembly from the

engine, ensuring that the torque convertor is

removed with the gearbox and does not stay

on engine.

Refitting

46.

47.

48.

49.

Ref i t t ing the gearbox is a reversa l o f the

r e m o v a l p r o c e d u r e n o t i n g t h e f o l l o w i n g

points.

The flexib le drive piate to torqu e c onve rter

bolts are to be coated with Loctite 270 prior

to assembly.

Tighten a ll fasteners to the spe cified torque

values.

New gaskets are to be fitted to the exhaust

flanges, all joints other than those fitted with

doughnuts, to be coated with exhaust sealer.Check the system, if any leaks are evident

resea l as nec essary.

ADDITION: SEPT. 8873 .


74/74

Documents

44 Automatic Gearbox