Land Rover Defender V8i Workshop Supplement Rover Manual

							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
8Nm(6
lbf.ft).
21.Remove setting gauge.
22.Refit gearbox fluid pan
See Fluid pan gasket
and screen; Refit.
23.Lower vehicle on ramp.
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.
2.Disconnect battery negative lead. Raise vehicle.
3.Disconnect inhibitor switch multiplug.
4.Remove inhibitor switch retaining plate.
5.Remove inhibitor switch.
6.Remove and discard 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. 
						

							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.
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 discard 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
transmission fluid 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. Fit filler tube union nut and tighten
to
70 Nm (52 lbf.ft). 
						

							44AUTOMATIC GEARBOX
4
REPAIR 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; Refit
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.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; Refit
See Gearbox and transfer box assembly 
						

							AUTOMATIC GEARBOX
5
REPAIR 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.
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 NEW 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, 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 - 0.016in). Replace existing
washer, situated at rear of intermediate plate,
with a washer selected to give required end float. 
						

							44AUTOMATIC GEARBOX
6
REPAIR 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; Refit
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 MAINTENANCE ,
under vehicle maintenance
5.Drain transfer gearbox oil.See 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. 
						

							AUTOMATIC GEARBOX
7
REPAIR
13.Remove split pin and clevis pin securing hand
brake cable to lever. Discard split pin.
14.Remove 2 screws securing fan cowl to upper
retaining brackets.
15.Release 2 clips securing upper fan cowl.
16.Remove upper fan cowl.
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 
						

							44AUTOMATIC GEARBOX
8
REPAIR
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.
33.Using a centre punch, mark relationship between
front propeller shaft to transfer box flanges.
34.Using a centre punch, mark relationship between
rear propeller shaft to brake drum flanges.
35.Remove 4 nuts securing front propeller shaft to
transfer box flange.
NOTE: Rotate propeller shaft to gain
access to all fixing.
36.Release propeller shaft from transfer box flange
bolts and tie aside.
37.Remove 4 nuts securing rear propeller shaft to
brake drum flange.
NOTE: Rotate propeller shaft to gain
access to all fixing.
38.Release propeller shaft from brake drum bolts
and tie aside.
39.Remove 7 bolts securing bell housing closing
plate and remove plate.
40.Remove 3 bolts securing bell housing access
plate and remove plate. 
						

							AUTOMATIC GEARBOX
9
REPAIR
41.Mark relationship between converter and drive
plate.
42.Rotate crankshaft to access drive plate to
converter fixing.
43.Remove 4 bolts securing drive plate to
converter.
44.Fit suitable piece of wood through bell housing
access hole to retain converter.
45.Remove clamp bolt securing gearbox cooler
pipes to engine sump bracket.
46.Loosen gearbox cooler pipe unions and
disconnect from gearbox.
47.Remove and discard O rings from pipes.
CAUTION: Plug the connections.
48.Tie cooler pipes aside.
49.Loosen gearbox filler tube union and remove
from fluid pan.
50.Remove and discard O ring from union.
CAUTION: Plug the connections. 
						

							44AUTOMATIC GEARBOX
10
REPAIR
51.Remove split pin from selector cable yoke and
collect washer. Discard split pin.
52.Release yoke from lever.
53.Remove bolt securing selector outer cable clamp
to transfer box LH mounting.
54.Remove nut securing oxygen sensor multiplug
bracket from transfer box earth bolt and collect
bracket.
55.Remove nut securing earth strap to transfer box
and release strap.
56.Release hand brake outer cable from body.
57.Remove bolt securing earth lead to RH side of
transfer box.
58.Fit transmission cradleLRT-99-008Ato
transmission jack.
59.Fit and tighten bolts securing cradle to jack.
60.Remove 2 lower bolts securing transfer box rear
cover.
61.Collect hand brake cable heat shield.
62.Raise jack and align cradle to transmission.
63.Refit previously removed transfer box rear cover
bolts to secure cradle. 
						

							AUTOMATIC GEARBOX
11
REPAIR
64.Remove 2 nuts and bolts securing heat shield to
transfer box LH mounting bracket.
65.Remove heat shield.
66.Remove 3 nuts and bolts securing transfer box
LH mounting bracket to chassis.
67.Release earth lead from fixing.
68.Remove nut securing transfer box RH mounting.
69.Remove 3 nuts and bolts securing transfer box
RH mounting bracket to chassis.
70.Remove transfer box RH mounting bracket and
collect flexible mount heat shield.
71.Lower transmission on jack to access harness
connectors.72.Disconnect the following multiplugs/connectors
from transfer box:
Speed transducer
Parking solenoid
Neutral detection switch
Differential lock
Temperature sensor switch
73.Remove 2 cable ties securing harness to
transfer box.
74.Position jack to support engine sump.
CAUTION: Use a block of wood or hard
rubber pad to protect sump.
75.Remove 2 remaining bell housing to engine
bolts.
76.With assistance, lower transmission and engine
jacks until hi-low selector lever is clear of
transmission tunnel aperture.
77.Separate transmission from engine and lower on
jack.
78.Remove transmission assembly from beneath
ramp.
79.Position lifting eyes to transmission and secure
with bolts.
80.Fit lifting chains to eyes and connect.
81.Position lifting hoist and connect lifting chains.
82.Raise hoist until chains are taught.
83.Remove bolts securing cradle to transfer box.
84.Raise transmission from cradle.
85.Refit transfer box rear cover plate bolts.
86.Lower transmission assembly onto work bench.
87.Disconnect lifting chains from eyes.
88.Remove bolts securing eyes to transmission and
remove eyes.
Refit
89.Position lifting eyes to transmission and secure
with bolts.
90.Connect lifting chains to eyes.
91.Raise transmission assembly from bench and
position above transmission cradle.
92.Remove 2 transfer box rear cover plate bolts.
93.Lower transmission onto cradle, align to transfer
box rear cover plate and secure with previously
removed bolts.
94.Lower hoist and disconnect lifting chains from
eyes.
95.Remove chains from hoist.
96.Remove bolts securing lifting eyes to
transmission and remove eyes.