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Land Rover Range Rover 2002my On Workshop Procedures Lm 6th Edition Nas Rover Manual
Land Rover Range Rover 2002my On Workshop Procedures Lm 6th Edition Nas Rover Manual
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TRANSFER BOX 41-12 REPAIRS Fuse - transfer gearbox - electronic control unit (ECU) $% 41.20.75 Remove 1.Remove battery carrier. + CHARGING AND STARTING, REPAIRS, Carrier - battery. 2.Release clips securing ECU cover to bulkhead. Remove cover. 3.Carefully release 2 clips and remove fuse box cover. 4.Locate fuse, remove 2 nuts and collect spacers. Remove and discard fuse.Refit 1.Ensure fuse box terminals are clean. 2.Position fuse, fit spacers and nuts, tighten to 6 Nm (4.4 lbf.ft). 3.Fit fuse box cover. 4.Fit and secure ECU cover. 5.Fit battery carrier. + CHARGING AND STARTING, REPAIRS, Carrier - battery. M41 7823 M41 7825
TRANSFER BOX REPAIRS 41-13 Damper - vibration - Td6 $% 41.20.85 Remove 1.Remove front propeller shaft. + DRIVESHAFTS, REPAIRS, Propeller shaft - front. 2.Remove 3 Torx screws securing mass damper and remove damper. Refit 1.Clean damper and mating face. 2.Fit damper and tighten Torx screws to 23 Nm (17 lbf.ft). 3.Fit front propeller shaft. + DRIVESHAFTS, REPAIRS, Propeller shaft - front. Electronic control unit (ECU) - transfer gearbox $% 41.30.01 If the ECU is to be replaced then Testbook/T4 must be connected and correct procedures adhered to, prior to battery disconnection. Remove 1.Remove battery. + CHARGING AND STARTING, REPAIRS, Battery. 2.Release clips securing ECU cover to bulkhead. Remove cover. 3.Release 2 clips securing ECU to bulkhead mounting bracket. 4.Release ECU from mounting, disconnect 3 multiplugs and remove ECU. M41 7832 M41 7823
TRANSFER BOX 41-14 REPAIRS Refit 1.Position ECU, connect and secure multiplugs. 2.Fit ECU to mounting and secure clips. 3.Fit and secure cover. 4.Fit battery. + CHARGING AND STARTING, REPAIRS, Battery. Actuator - ratio control $% 41.30.03 Remove 1.Position vehicle on lift and select Low Range. 2.Switch off ignition. 3.With neutral selected on automatic gearbox, check that a fuse is not fitted in position 37 of main fuse box. Remove fuse if fitted. 4.Raise the lift. 5.Ensure area to be dismantled is clean. 6.Position a container to collect any spillage. 7.Rotate multiplug anti-clockwise to release and disconnect from ratio control actuator. 8.Remove 3 bolts securing ratio control assembly to transfer gearbox.
TRANSFER BOX REPAIRS 41-15 9.Avoid disturbing the lead screw which should remain with the transfer gearbox. With extreme care, slowly release the ratio control assembly from the transfer gearbox. Use a small flat blade screw driver to prevent the lead screw moving out with the ratio control assembly, as shown. CAUTION: If the lead screw is rotated or withdrawn internal transfer gearbox damage may result. 10.Remove the O ring. 11.Remove bearing only if released. Refit 1.Ensure low range is selected by pushing selector shaft fully into transfer gearbox. CAUTION: If the lead screw is rotated or withdrawn internal damage may result. 2.Clean bearing and mating face. 3.Lubricate and fit bearing, with legs of bearing pointing towards the transfer gearbox, as shown.4.Clean ratio control assembly and mating face on transfer gearbox. 5.Use a new O ring, engage splines and fit ratio control assembly to transfer gearbox. NOTE: The lead screw has a master spline. 6.Fit and tighten bolts securing ratio control assembly to transfer gearbox to 28 Nm (21 lbf.ft). 7.Connect and secure multiplug to ratio control actuator. 8.Lower the lift. 9.To calibrate a new ratio control assembly, follow the steps below. 10.Fit spare fuse into position 37 in main fuse box. 11.With automatic gearbox in neutral, switch ignition on. 12.Switch off ignition. 13.Remove fuse from position 37. 14.Switch ignition on. 15.Operate switch to perform a high to low shift and back to high. 16.Drive vehicle to perform at least 3 high to low to high shifts cycles at permissible speeds above 6 mph (10 km/h).
AUTOMATIC TRANSMISSION - ZF 5HP24 ADJUSTMENTS 44-2-1 AUTOMATIC T RANSMIS SION - ZF 5HP24 ADJUST ME NTS Gearbox fluid - drain & refill $% 44.24.02 Drain 1.Position vehicle on lift. WARNING: Observe due care when draining gearbox fluid as the fluid can be very hot. 2.Apply handbrake and position chocks under front and rear wheels. 3.Position container under gearbox. NOTE: The fluid should be drained with the transmission at normal operating temperature. 4.Clean area around drain plug. 5.Remove drain plug and discard sealing washer. 6.Allow fluid to drain. 7.Clean sump drain plug, fit new sealing washer and tighten to 25 Nm (18 lbf.ft). Refill 1.Clean area around filler/level plug.2.Remove filler/level plug and discard sealing washer. 3.Add 3.5 to 4.0 litres of correct fluid through gearbox level/filler hole. 4.Fit new sealing washer and tighten filler/level plug to 35 Nm (26 lbf.ft). 5.Check and top-up fluid level. + MAINTENANCE, PROCEDURES, Gearbox fluid - V8. M44 1806 M44 1807
AUTOMATIC TRANSMISSION - ZF 5HP24 44-2-2 ADJUSTMENTS Selector cable - check and adjust $% 44.30.04 Check 1.Move selector lever from P, check gear engagement in each position and return to P. 2.Check that the engine will start in P and N positions and that engine start is inhibited when drive positions are selected. Adjust 1.Position vehicle on lift. 2.Move the selector lever to P position. 3.Raise vehicle on lift. 4.Using 2 spanners, restrain trunnion and loosen nut securing inner cable to selector lever. 5.Move selector lever on gearbox fully clockwise to engage P position. 6.Tighten trunnion nut to 15 Nm (11 lbf.ft). 7.Lower vehicle on lift. 8.Move selector lever from P, check gear engagement in each position and return to P. 9.Check that the engine will start in P and N positions and that engine start is inhibited when drive positions are selected. M44 1805
AUTOMATIC TRANSMISSION - ZF 5HP24 REPAIRS 44-2-3 REPAIRS Lever - gearshift selector assembly $% 44.15.04 Remove 1.Remove centre console. + INTERIOR FITTINGS, REPAIRS, Centre console. 2.Disconnect shift interlock cable from ignition barrel. 3.Remove clip securing outer gear shift cable to mechanism. 4.Release and remove clip securing inner gear shift cable to mechanism, collect plastic spacer from cable. 5.Disconnect 2 multiplugs from selector mechanism. 6.Remove 3 nuts securing selector mechanism to carrier, remove mechanism. Refit 1.Position mechanism to carrier, fit nuts and tighten to 25 Nm (18 lbf.ft). 2.Connect multiplugs to mechanism. 3.Fit plastic spacer to selector cable, secure cable to mechanism. 4.Connect shift interlock cable to ignition switch barrel. 5.Fit centre console. + INTERIOR FITTINGS, REPAIRS, Centre console. Knob - selector lever $% 44.15.07 Remove 1.Release 4 clips securing gear-lever gaiter to centre console. 2.Pull gear knob upwards to disengage locating tang from gear selector lever. WARNING: Gear knob will be released suddenly, keep face clear of gear knob during removal. Refit 1.Position gear knob to gear selector lever engaging locating tang on knob with slot in selector lever. 2.Push gear knob fully on to gear selector lever. 3.Fit and secure gear lever gaiter. M44 1917
AUTOMATIC TRANSMISSION - ZF 5HP24 44-2-4 REPAIRS Rod/cable assembly - selector $% 44.15.08 Remove 1.Position vehicle on lift. 2.Select P. 3.Remove centre console. + INTERIOR FITTINGS, REPAIRS, Centre console. 4.Remove clip securing outer gear shift cable to mechanism. 5.Release and remove clip securing inner gear shift cable to mechanism, collect plastic spacer from cable. 6.Loosen nut securing selector cable to selector lever and release selector cable from bracket. 7.Remove cable and grommet through carpet access panel.Refit 1.Position cable through access panel, fit grommet and carpet. 2.Position selector cable through bracket and selector lever and secure selector cable to bracket. 3.Tighten nut securing selector cable to selector lever to 15 Nm (11 lbf.ft). 4.Position cable to selector mechanism, fit spacer and secure with clips. 5.Fit centre console. + INTERIOR FITTINGS, REPAIRS, Centre console.
AUTOMATIC TRANSMISSION - ZF 5HP24 REPAIRS 44-2-5 Switch - starter inhibitor $% 44.15.19 Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. + GENERAL INFORMATION, Electrical Precautions. Remove 1.Disconnect battery earth lead. 2.Remove air intake plenum. + HEATING AND VENTILATION, REPAIRS, Plenum - air intake. 3.Disconnect multiplug from inhibitor switch. 4.Remove bolt securing inhibitor switch multiplug bracket and release harness from gearbox. 5.Disconnect breather hose from gearbox. 6.Raise vehicle on lift. 7.Release inhibitor switch harness from retaining clips and position aside. 8.Remove nut securing selector lever to inhibitor switch and release lever.9.Remove 2 bolts securing inhibitor switch guard and remove guard. 10.Remove 2 bolts securing inhibitor switch to gearbox and remove inhibitor switch. Refit 1.Clean inhibitor switch and mating face on gearbox. 2.Fit inhibitor switch onto dowel, fit bolts and tighten to 10 Nm (7 lbf.ft) 3.Fit and secure inhibitor switch harness and connect multiplug. 4.Position inhibitor switch harness bracket, fit and tighten bolt to 10 Nm (7 lbf.ft) 5.Fit inhibitor switch guard, fit and tighten bolts to 10 Nm (7 lbf.ft) 6.Fit selector lever to inhibitor switch, fit nut and tighten to 10 Nm (7 lbf.ft) 7.Lower vehicle. 8.Connect breather hose to gearbox. 9.Fit air intake plenum. + HEATING AND VENTILATION, REPAIRS, Plenum - air intake. 10.Connect battery earth lead. M44 1856