Land Rover Defender 90 Workshop 2nd Edition Nas Rover Manual
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44AUTOMATIC GEARBOX 4 DESCRIPTION AND OPERATION Reverse gear Clutches 5, 8 and 11 are engaged. Since the front planet gear carrier of epicyclic gear set 9 is locked, the direction of output-shaft rotation is reversed. Epicyclic gear set 10 also rotates as a solid block.
AUTOMATIC GEARBOX 1 FAULT DIAGNOSIS ZF AUTOMATIC GEARBOX Before referring to fault symptoms, carry out initial static checks first: INITIAL STATIC CHECKS Check start positions P & N only........................................................ Reverse lights R only.................................................................. Gear engagements N-D,N-3,N-2,N-1,N-R.......................................................... Full throttle Engine switched off, check full travel at engine and at....................................................................... pedal. Oil level N selected, engine running at normal running............................................................................ temperature. Pressure test 2000 rev/min 10±0.3 bar .................................................................... 150±5 lbf/in 2 Idle pressure at 665 to 735 rev/min. 6.9±0.3 bar ................................. 100±5 lbf/in2 To fit pressure gauge Service tools: See Service tools, Automatic Gearbox Pressure gauge 0 to 20 bar, 0 to 300 lbf/in2. Flexible hose adaptor. 1.Site vehicle on a ramp [hoist]. 2.From under gearbox, remove socket head plug (located 10cm, 4 in from oil pipe). Fit hose adaptorLST502-1. 3.Fit hose to adaptor. 4.Fit gauge18G502Ato hose and route into vehicle, ensuring hose is clear of rotating parts and exhaust pipes. 5.Carry out road test. See Road Test Procedure 6.Remove pressure gauge
44AUTOMATIC GEARBOX 2 FAULT DIAGNOSIS ROAD TEST PROCEDURE Follow the procedure given commencing each test, from a standing start, on a level road, in good weather conditions. ROADTEST 1 = CHECKS 1-2-3-4-5-6-7-8 D SELECTED KICKDOWN START FROM REST CHECK 1 Check for clutch squeal and slip. Check pressure is 150lbf/in 2 CHECK 2 Check 1st to 2nd upshift speed and quality. Pressure should fall to 120 lbf/in 2. CHECK 3 Check 2nd to 3rd upshift speed and quality. Pressure should fall to 100 lbf/in 2 CHECK 4 Release throttle to allow simultaneous engagement 4th + DDC. Check shift quality and engine rpm drop of approximately 500 rpm. CHECK 5 To proceed to Check 5, release throttle and check drop out speed of direct drive clutch to 4th. CHECK 6 Check down shift speed and quality 4th to 3rd. NOTE: This shift is usually very smooth and difficult to detect. CHECK 7 Check downshift speed and quality 3rd to 2nd. CHECK 8 Check downshift speed and quality 2nd to 1st. Also difficult to detect.ROADTEST 2 = CHECKS 9-10-11 D SELECTED FROM REST FULL THROTTLE START CHECK 9 Check 1st to 2nd upshift speed and quality. CHECK 10 Check 2nd to 3rd upshift speed and quality. CHECK 11 Check 3rd, 4th and direct drive clutch upshift speed and quality. NOTE: 4th and the direct drive clutch engage simultaneously.
AUTOMATIC GEARBOX 3 FAULT DIAGNOSIS ROADTEST 3 = CHECKS 12-13-14-15-16-17-18-19-20-21-22-23 D SELECTED FROM REST LIGHT THROTTLE START CHECK 12 Check 1st to 2nd upshift speed and quality. CHECK 13 Check 2nd to 3rd upshift speed and quality. CHECK 14 Check 3rd to 4th upshift speed and quality. NOTE: This shift is usually very difficult to detect but can be confirmed by a 200 rpm drop in engine speed. CHECK 15 Check speed and quality of shift into direct drive clutch, confirmed by 300 rpm drop in engine speed. NOTE: An intermediate throttle position engagement of 4th and the direct drive clutch, which is indicated by a fall of 500 rpm in engine speed. CHECK 16 At approximately 88 kph, 55 mph depress throttle to kickdown - gearbox should change down to 2nd - release throttle to re-engage 4th direct drive clutch continue to accelerate gently. CHECK 17 At approximately 128 kph, 80 mph depress throttle to kickdown - gearbox should change down to 3rd - release throttle to re-engage 4th direct drive clutch and continue to accelerate gently.CHECK 18 At approximately 138 kph, 85 mph select 3rd, gearbox should change immediately down to 3rd. Release throttle. CHECK 19 De-accelerate to approximately 47 kph, 30 mph depress throttle to kickdown - geabox should downshift to 1st gear, continue accelerating at full throttle until 3rd gear is attained. To do this you will have repeated check 2 of Test 1. CHECK 20 At 128 kph, 80 mph select 2nd no downshift should occur. Release throttle. CHECK 21 At 104 kph, 65 mph an automatic downshift into 2nd gear should occur. Continue to de-accelerate. CHECK 22 At 88 kph, 55 mph select 1st. No downshift should occur. Continue to de-accelerate. CHECK 23 With 1 selected 2nd gear engaged, continue to de-accelerate and at 45 kph, 28 mph the box should automatically downshift to 1st gear after which no upshifts will occur in this selector position. END OF ROADTEST
44AUTOMATIC GEARBOX 4 FAULT DIAGNOSIS AUTOMATIC GEARBOX ASSEMBLY 1. Gearbox assembly 2. Inhibitor switch assembly 3. Control unit assembly 4. Filter and sump assembly
AUTOMATIC GEARBOX 5 FAULT DIAGNOSIS 1. Torque converter housing assembly 2. Gearbox pump and casing assembly 3. Governor and adaptor housing assembly
44AUTOMATIC GEARBOX 6 FAULT DIAGNOSIS 1. A Clutch assembly 2. B Clutch assembly
AUTOMATIC GEARBOX 7 FAULT DIAGNOSIS 1. C,C and D Clutch assembly
44AUTOMATIC GEARBOX 8 FAULT DIAGNOSIS 1. Freewheel and fourth gear assembly
AUTOMATIC GEARBOX 9 FAULT DIAGNOSIS 1. E and F Clutch assembly