Land Rover Defender 90 Workshop 2nd Edition Nas Rover Manual

							44AUTOMATIC GEARBOX
10
FAULT DIAGNOSIS FAULT SYMPTOMS
SYMPTOM 1 - Intermittent drive and high pitched
noise
FAULT - Low fluid level or restricted filter
SYMPTOM 2 - No drive in reverse
Select D
·No drive
FAULT - Continue with Symptom 3
·Drives forward
FAULT - Reverse gear interlock valve seized
Select 1
·No engine braking
FAULT - Clutch brake 3
SYMPTOM 3 - No drive from rest with D selected
Select 1
·Vehicle drives
FAULT - No 2 freewheel
·No drive
Carry out main line pressure check
·Normal pressure
FAULT - Clutch A
·No pressure
FAULT - Blocked filter or pump failure
·Low pressure
FAULT - Restricted filter or sticking primary
regulator
SYMPTOM 4 - Slip in all forward gears
Carry out main line pressure check
·No pressure
FAULT - Blocked filter or pump failure
·Low pressure
FAULT - Restricted filter or sticking primary
regulator
·Normal pressure
FAULT - Clutch ASYMPTOM 5 - Harsh engagement N to D
Check engine idle speed
Carry out main line pressure check
·High pressure
FAULT - Primary regulator stuck
·Normal pressure
FAULT - Clutch A or damper for clutchA
SYMPTOM 6 - Fierce shift or flare 1st to 2nd shift
Check engine idle speed
Carry out mainline pressure check
·High pressure
FAULT - Continue with symptom 5
·Normal pressure
FAULT - Modulator valve or dampers for clutch
brake CB1 and/or clutch brake CB2
FAULT - Clutch brake CB1 and/or clutch brake
CB2
SYMPTOM 7 - Fierce shift or flare 2nd to 3rd
Carry out mainline pressure check
·High pressure
FAULT - Continue with symptom 5
·Normal pressure
FAULT - Modulator valve or clutch B damper
FAULT - Clutch B
SYMPTOM 8 - No 3rd gear
FAULT - 2-3 shift valve
FAULT - Clutch B
SYMPTOM 9 - No 4th gear D selected
FAULT - 4th to 3rd downshift valve stuck or 3rd
to 4th upshift valve stuck
FAULT - Clutch brake 4 
						

							AUTOMATIC GEARBOX
11
FAULT DIAGNOSIS SYMPTOM 10 - None or harsh engagement of
direct drive clutch
NOTE: The direct drive clutch will only
engage if 4th gear is engaged at 40 to 45
mph.
Carry out road test pressure check with gauge
connected to torque converter.
·Normal pressure
FAULT - Failed direct drive clutch
·Pressures correct but remains high
FAULTS POSSIBLE -
Direct drive clutch and torque converter control
valve stuck
Hysteresis valve stuck
Direct drive clutch control valve stuck
SYMPTOM 11 - Direct drive clutch shift point
incorrect or at low speed
NOTE: Direct drive clutch engagement at
low speed will cause vibration in the
torque converter
Carry out mainline and torque converter pressure
check
·Normal pressure
FAULT - Governor valve sticking
·Low or incorrect pressure
FAULTS POSSIBLE -
Direct drive clutch and torque converter control
valve sticking.
Hysteresis valve stuck.
Direct drive clutch control valve stuck.
SYMPTOM 12 - Drives in D but immediately
upshifts to 3rd
FAULT - 2nd to 3rd shift valve stuck.
SYMPTOM 13 - With D selected vehicle starts in
2nd
FAULTS POSSIBLE -
1st and 2nd shift valve stuck.
Governor sleeve sticking.
SYMPTOM 14 - With D selected vehicle starts in
3rd
FAULTS POSSIBLE -
1st to 2nd and 2nd to 3rd shift valves stuck.
Governor sleeve sticking.SYMPTOM 15 - No kickdown 4th to 3rd
FAULT - 4th to 3rd kickdown valve stuck.
SYMPTOM 16 - Upshifts/downshifts and kickdown
shifts at incorrect road speeds
Check throttle kickdown cable adjustment
Carry out main line pressure check
·Normal pressure
FAULT - Governor valve sticking
·Incorrect pressure
FAULTS POSSIBLE -
Incorrect throttle valve adjustment
Primary regulator sticking
SYMPTOM 17 - No upshifts at light throttle
FAULTS POSSIBLE
Governor valve sticking
Shift valves sticking
SYMPTOM 18 - No engine braking 3 selected 3rd
gear
FAULT - Clutch C
SYMPTOM 19 - Delayed or no downshift occurs
when making a manual selection from 3 to 2
FAULTS POSSIBLE -
2nd and 3rd upshift valve sticking.
Governor valve sticking.
2 Position interlock valve sticking.
SYMPTOM 20 - At speeds below 28 mph when
making a manual selection from 2 to 1,
downshift is delayed or does not occur
FAULTS POSSIBLE -
Governor sticking.
1st to 2nd shift valve sticking.
1 Position interlock valve sticking.
SYMPTOM 21 - 1 Selected 1st gear no engine
braking
FAULT - Clutch brake 3
SYMPTOM 22 - 2 Selected 2nd gear no engine
braking
FAULT - Clutch brake 1
SYMPTOM 23 - Vehicle drives forward in N
FAULT - Clutch A stuck 
						

							AUTOMATIC GEARBOX
1
ADJUSTMENT KICKDOWN CABLE ADJUSTMENT
Service repair no - 44.30.02
1.Release and remove kick-down cable clevis pin.
2.Loosen locknut and release kickdown cable from
abutment bracket.
3.Release outer cable sleeve from clip on rear of
LH cylinder head.
4.Holding cable as straight as possible, extend
inner cable to first detent.
5.With inner cable extended, check dimensionA
between end of threads and crimped sleeve.
DimensionA=42mm±3 mm, 1.65±0.10 in.
6.Connect cable to abutment bracket and fit
locknut.
7.Secure outer cable sleeve to clip on rear of LH
cylinder head.
8.Connect kick-down cable to throttle lever and
secure with clevis pin.9.Adjust outer cable until crimped sleeve is
dimensionBfrom end of outer cable.
DimensionB= 1 mm, 0.04 in.
10.Tighten locknut. 
						

							AUTOMATIC GEARBOX
1
REPAIR KICKDOWN CABLE
Service repair no - 44.15.01
Remove
1.Site vehicle on a four post ramp [hoist].
2.Select neutralN.
3.Disconnect battery negative lead.
4.Remove clevis pin and release kickdown cable
at throttle linkage.
5.Release outer cable locknut.
6.Disconnect cable from abutmet bracket.
7.Release cable from retaining clip at bracket
attached to cylinder head.
8.Feed cable through to underside of vehicle.
9.Raise vehicle on ramp [hoist].
10.Remove gearbox fluid pan
See Fluid pan
gasket and screen.
11.Remove 13 bolts securing control unit assembly
to gearbox.
12.Rotate accelerator cam and release nipple of
kickdown inner cable from cam.
13.Using special toolLRT-44-004, compress cable
tangs and remove cable from gearbox.
14.If cable is to be refitted, remove O ring seal and
clean cable assembly.
Refit
15.Fit NEW O ring seal to cable and lubricate seal.
16.Fit cable to gearbox casing ensuring it is
correctly seated.
17.Spring load cam by turning once and fit inner
cable nipple into cam seat.
NOTE: When a new cable is fitted, to help
locate nipple to cam, introduce a curve
into the cable. DO NOT bend or kink cable.
18.Ensuring cable nipple remains engaged, feed
free end of cable assembly into engine
compartment.
19.Locate control unit assembly to gearbox and
loosely fit 13 bolts. Ensure selector shaft locates
into gear shift fork. 
						

							44AUTOMATIC GEARBOX
2
REPAIR
20.Locate selector linkage setting gauge
LRT-44-002in position and gently press control
unit forwards as shown. Tighten bolts to
8 Nm, 6
lbf ft.
21.Remove setting gauge.
22.Refit gearbox fluid pan
See Fluid pan gasket
and screen.
23.Lower vehicle on ramp [hoist].
24.Adjust kickdown cable
See Adjustment,
Kickdown cable adjustment.
25.Reconnect battery negative lead.
26.Refill gearbox oil using correct grade of oil
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended Lubricants and
Fluids.
INHIBITOR SWITCH
Service repair no - 44.15.19
Remove
1.Site vehicle on a four post ramp [hoist].
2.Disconnect battery negative lead. Raise vehicle.
3.Disconnect inhibitor switch multiplug.
4.Remove inhibitor switch retaining plate.
5.Remove inhibitor switch.
6.Remove O ring seal.
7.Clean inhibitor switch.
Refit
8.Clean mating face on casing.
9.Fit and lubricate NEW O ring seal to switch.
10.Fit switch to casing.
11.Secure with retaining plate and bolt.
12.Connect multiplug to harness.
13.Reconnect battery and remove vehicle from
ramp [hoist]. 
						

							AUTOMATIC GEARBOX
3
REPAIR FLUID PAN GASKET AND SCREEN
Service repair no - 44.24.05 - Fluid pan gasket
Service repair no - 44.24.07 - Fluid screen
Remove
1.Site vehicle on a four post ramp [hoist].
2.Disconnect battery negative lead.
3.Raise vehicle.
4.Drain fluid and refit plug with new seal. Tighten
to
43 Nm, 32 lbf ft.
5.Remove catalytic converter assemblySee
EMISSION CONTROL, Repair, Front
pipe/catalytic converter.
6.Release fuel pipes from retaining clip secured by
top RH chassis crossmember bolt.
7.Remove 8 bolts securing chassis crossmember.
8.With assistance and using a body jack between
chassis longitudinals, jack chassis sufficiently to
enable removal of crossmember.
9.Disconnect dipstick tube from fluid pan. Loosen
securing bolt at bell housing and move tube
aside.
10.Remove clamps securing fluid pan. Note their
locations for refit and withdraw pan.
11.Remove gasket and clean gasket mating faces.
12.Remove securing screws and detach oil screen
and suction pipe, taking care to retain suction
pipe spacer, discard O ring seal.
13.Detach suction pipe from fluid screen, discard
O ring seal.
Refit
14.Clean fluid screen and blow out with airline.
15.Clean suction pipe.
16.Fit new O ring seals to fluid screen using light
grease to aid assembly.
17.Fit fluid screen and suction pipe with spacer and
secure with bolts. Tighten to
8 Nm, 6 lbf ft.
18.Refit fluid pan using a NEW gasket. Tighten to8
Nm, 6 lbf ft.
19.Connect dipstick tube to fluid pan, tighten bolt at
bell housing. Filler tube union nut Tighten to
70
Nm, 52 lbf ft.
20.Position both exhaust heat shields and refit
chassis cross-member. Secure fuel pipes to
retaining clip.
21.Refit catalytic converter assembly
See
EMISSION CONTROL, Repair, Front
pipe/catalytic converter.
22.Connect battery.
23.Refill transmission using correct grade of fluid
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids.
24.Apply parking brake and with selector at P, run
engine at idle.
25.Apply footbrake, from P, move selector to
position 1 and back to N. Check fluid level, this
must be between the level marks. Top-up as
necessary. 
						

							44AUTOMATIC GEARBOX
4
REPAIR TORQUE CONVERTER
Service repair no - 44.17.04
Remove
1.Remove gearbox and transfer box assembly,
See Gearbox and transfer box assembly
2.Place gearbox on bench. Remove torque
converter using torque converter handle
LRT-44-010, taking care not to damage torque
converter/oil pump housing oil seal.
Refit
3.Fit NEW torque converter using torque converter
handlesLRT-44-010. Check dimension from
converter fixing boss to converter housing face is
50 mm, 1.968 in. This shows converter is
correctly seated in housing.
4.Refit gearbox and transfer box assembly.
See
Gearbox and transfer box assembly
PUMP AND MAIN HOUSING
Service repair no - 44.20.11 - Intermediate plate
gasket
Service repair no - 44.32.01 - Pump assembly
Service repair no - 44.32.07 - Pump oil seal
Remove
1.Remove gearbox and transfer box assembly,
See Gearbox and transfer box assembly
2.Place gearbox on bench. Remove torque
converter using torque converter handles
LRT-44-010, taking care not to damage torque
converter/oil pump housing oil seal.
3.Remove 12 bolts (inner ring of bolts).
4.Remove bell housing and pump assembly,
discard gasket.
5.Remove 8 bolts from rear of pump. 
						

							AUTOMATIC GEARBOX
5
REPAIR 6.Screw in 2 bolts, diagonally opposite each other.
Tap lightly using a soft headed mallet to remove
pump assembly from intermediate plate.
7.Remove shaft sealing ring and O ring from
pump housing and discard.
Refit
8.Using oil seal replacerLRT-44-001fit shaft seal
ring into pump housing.
9.Fit O ring onto circumference of pump housing.
10.Align dowel with hole in intermediate plate and
press pump housing home.
11.Fit pump housing to intermediate plate, tighten
bolts to
10 Nm, 7 lbf ft.
12.Place bell housing and intermediate plate
assembly on bench, front face up. Using oil
pump rotation sleeveLRT-44-003(LST111),
check that pump gears rotate freely.
13.Before fitting intermediate plate and bell housing
assembly, check that thrust washer and axial
cage are seated on clutch housing.
14.Place NEW gasket and selective disc washer
onto bell housing and intermediate plate
assembly using Petroleum Jelly.
15.Fit bell housing and intermediate plate assembly
to gearcase. Tighten bolts to
46 Nm, 34 lbf ft.
16.Place end float gaugeLRT-44-003onto pump
housing and check that axial play is between 0.2
- 0.4 mm, 0.008 - 0.016 in. Replace existing
washer, situated at rear of intermediate plate,
with a washer selected to give required end float.17.Refit torque converter into housing using torque
converter handlesLRT-44-010. Check that
dimension from converter fixing bolt boss to
converter housing face is 50 mm, 1.968 in to
comfirm that converter is properly seated in
housing.
18.Refit gearbox/transfer box assembly.
See
Gearbox and transfer box assembly 
						

							44AUTOMATIC GEARBOX
6
REPAIR GEARBOX AND TRANSFER BOX ASSEMBLY
Service repair no - 44.20.04/99
Remove
1.Position vehicle on 4-post ramp.
2.Select LOW range gear and leave vehicle in
neutral.
3.Disconnect battery negative lead.
4.Drain gearbox oil.
See SECTION 10,
Maintenance, under vehicle maintenance
5.Drain transfer gearbox oil.See SECTION 10,
Maintenance, under vehicle maintenance
6.Remove centre console.See CHASSIS AND
BODY, Repair, centre console
7.Remove carpet from transmission tunnel.
8.Remove hi-low selector housing cover from
tunnel.
9.Working through hi-low gear lever aperture,
disconnect inhibitor/reverse light switch
multiplug.
10.Remove 2 cable ties securing gearbox and
transfer box breather pipes to harness.
11.Remove 3 trim studs securing hand brake gaiter.
12.Release hand brake gaiter to access cable
linkage.
13.Remove split pin and clevis pin securing hand
brake cable to lever.
14.Remove 2 screws securing fan cowl to upper
retaining brackets.
15.Release 2 clips securing upper fan cowl.
16.Remove upper fan cowl. 
						

							AUTOMATIC GEARBOX
7
REPAIR
17.Remove kick-down cable clevis pin.
18.Release kick-down outer cable lock nut.
19.Release kick-down outer cable from abutment
bracket.
20.Release kick-down outer cable from clip on rear
of LH cylinder head.
21.Remove bolt securing 2 breather pipe P clips to
rear of RH cylinder head.
22.Remove 6 bell housing to engine bolts.
23.Raise vehicle.
24.Remove exhaust front pipe.
See EMISSION
CONTROL, Repair, front pipe/catalytic
converter
25.Remove 2 nuts securing intermediate pipe to tail
pipe.
26.Release intermediate pipe from tail pipe and
remove from mounting.
27.Remove 8 bolts securing chassis crossmember.
28.With assistance, and using a body jack between
chassis longitudinals, jack chassis sufficiently to
enable removal of crossmember.
29.Remove crossmember.
30.Remove body jack.
31.Remove bolt securing LH and RH catalyst heat
shields to chassis.
32.Remove catalyst heat shields.