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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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AUTOMATIC TRANSMISSION - ZF 5HP24 44-2-16 REPAIRS 25.Remove undertray. + EXTERIOR FITTINGS, REPAIRS, Undertray - front. 26.Remove grommet from bell housing to gain access to torque converter retaining bolts. 27.Rotate crankshaft for access and remove 4 bolts securing drive plate to torque converter. 28.Remove 2 bolts securing starter motor and tie aside.29.Remove bolt securing fluid cooler saddle clamp to sump. 30.Remove banjo bolt securing fluid cooler pipe to LH side of gearbox and discard sealing washers. 31.Release fluid cooler pipe from RH side of gearbox and discard O ring. 32.Remove 8 Torx bolts from bell housing. M44 1872 M44 1867
AUTOMATIC TRANSMISSION - ZF 5HP24 REPAIRS 44-2-17 33.With assistance, carefully remove gearbox from engine. Ensure torque converter remains with gearbox. 34.Fit converter retaining plate and secure with bolts. Refit 1.Clean mounting and mating faces. 2.Remove torque converter retaining plate. 3.With assistance, carefully fit gearbox to engine. Ensure engagement of torque converter spigot and gearbox housing onto dowels. 4.Fit 8 Torx bolts securing automatic gearbox to engine, tighten to 45 Nm (33 lbf.ft) 5.Clean fluid cooler pipes unions and mating faces. 6.Position fluid cooler pipe to LH side of gearbox. 7.Lubricate fluid cooler sealing washers with transmission fluid, fit banjo bolt to gearbox and tighten to 37 Nm (27 lbf.ft) 8.Fit and lubricate new O ring to fluid cooler pipe, fit pipe to gearbox and tighten to 37 Nm (27 lbf.ft). 9.Position fluid cooler saddle clamp, fit bolt and tighten to 6 Nm (4.4 lbf.ft) 10.Fit starter motor and tighten bolts to 45 Nm (33 lbf.ft). 11.Fit bolts securing drive plate to torque converter and tighten to 45 Nm (33 lbf.ft) 12.Fit grommet to gearbox bell housing. 13.Fit undertray. + EXTERIOR FITTINGS, REPAIRS, Undertray - front. 14.Fit oxygen sensor leads to gearbox casing. 15.Clean crankshaft sensor and mating face. 16.Position crankshaft sensor, fit bolt and tighten to 6 Nm (4.4 lbf.ft) 17.Position selector cable support bracket to gearbox, fit bolts and tighten to 10 Nm (7 lbf.ft) 18.Fit selector lever to inhibitor switch, fit nut and tighten to 10 Nm (7 lbf.ft)19.Fit and secure oxygen sensor leads to transfer gearbox. 20.Connect multiplug to gearbox connector. 21.Connect multiplug to high/low shift motor. 22.Raise gearbox on jack. 23.Fit snubbers. 24.Fit cross member to mounting, fit nut and bolt but do not tighten at this stage. 25.Align cross member, fit bolts and tighten to 68 Nm (50 lbf.ft). 26.Remove support from gearbox. 27.Tighten nut and bolt securing mounting to cross member to 100 Nm (74 lbf.ft). 28.Fit heat shield and secure with nuts. 29.Fit rear propeller shaft. + DRIVESHAFTS, REPAIRS, Propeller shaft - rear. 30.Fit front propeller shaft. + DRIVESHAFTS, REPAIRS, Propeller shaft - front. 31.Lower vehicle. 32.Fit top bell housing Torx bolts and tighten to 25 Nm (18 lbf.ft) 33.Fit and secure LH oxygen sensor lead to gearbox bell housing. 34.Connect inhibitor switch multiplug. 35.Fit air intake plenum. + HEATING AND VENTILATION, REPAIRS, Plenum - air intake. 36.Fit fan to pulley and tighten viscous coupling nut to 40 Nm (30 lbf.ft). 37.Connect battery earth lead. 38.Fill gearbox with fluid. + AUTOMATIC TRANSMISSION - ZF 5HP24, ADJUSTMENTS, Gearbox fluid - drain & refill. M44 1870
AUTOMATIC TRANSMISSION - ZF 5HP24 44-2-18 REPAIRS Fluid seal - rear $% 44.20.18 Remove 1.Remove transfer gearbox. + TRANSFER BOX, REPAIRS, Transfer gearbox - V8. 2.Remove 4 Torx bolts securing output flange housing and remove housing. 3.Remove bearing. 4.Carefully remove and discard oil seal and O ring. Refit 1.Clean housing and mating faces. 2.Using LRT-44-029 fit new oil seal. 3.Lubricate new O ring and fit to housing. 4.Lubricate and fit bearing. 5.Fit housing to gearbox, fit and tighten Torx bolts to 10 Nm (7 lbf.ft) 6.Fit transfer gearbox. + TRANSFER BOX, REPAIRS, Transfer gearbox - V8. Gasket - fluid pan $% 44.24.05 Remove 1.Drain gearbox fluid. + AUTOMATIC TRANSMISSION - ZF 5HP24, ADJUSTMENTS, Gearbox fluid - drain & refill. 2.Remove nut securing selector lever to gearbox selector shaft and release lever. 3.Remove 2 bolts securing inhibitor switch guard and remove guard. 4.Evenly and progressively loosen and remove 22 Torx bolts from sump. 5.Remove sump and discard gasket. M44 1859 LRT-44-029
AUTOMATIC TRANSMISSION - ZF 5HP24 REPAIRS 44-2-19 Refit 1.Clean gearbox sump mating surfaces. 2.Fit new gasket to sump, position sump to gearbox. 3.Evenly and progressively tighten sump Torx bolts to 10 Nm (7 lbf.ft). 4.Fit inhibitor switch guard, fit and tighten bolts to 10 Nm (7 lbf.ft) 5.Fit selector lever to inhibitor switch, fit nut and tighten to 10 Nm (7 lbf.ft) 6.Refill gearbox with transmission fluid. + AUTOMATIC TRANSMISSION - ZF 5HP24, ADJUSTMENTS, Gearbox fluid - drain & refill. Filter - fluid $% 44.24.07 Remove 1.Remove sump and discard gasket. + AUTOMATIC TRANSMISSION - ZF 5HP24, REPAIRS, Gasket - fluid pan. 2.Remove 2 Torx bolts and remove filter from valve block, discard O ring. Refit 1.Clean filter mating surfaces. 2.Ensure new filter has O ring fitted, then fit filter to valve block. 3.Fit Torx bolts to gearbox filter and tighten to 6 NM (4.4 lbf.ft). 4.Fit sump. + AUTOMATIC TRANSMISSION - ZF 5HP24, REPAIRS, Gasket - fluid pan. M44 1811
AUTOMATIC TRANSMISSION - ZF 5HP24 44-2-20 REPAIRS Fluid cooler $% 44.24.10 Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. + GENERAL INFORMATION, Electrical Precautions. Remove 1.Position vehicle on lift. 2.Disconnect battery earth lead. 3.Drain cooling system + COOLING SYSTEM - V8, ADJUSTMENTS, Coolant - drain, flush & refill. 4.Place container below gearbox fluid cooler. 5.Release quick release connectors and disconnect gearbox fluid cooler pipes from gearbox fluid cooler. CAUTION: Always fit plugs to open connections to prevent contamination.6.Release clip securing gearbox fluid cooler and remove gearbox fluid cooler from manifold. 7.Discard O rings. Refit 1.Clean gearbox fluid cooler mating faces. 2.Lubricate new O rings with clean transmission fluid and fit O rings to fluid cooler. 3.Fit gearbox fluid cooler to gearbox fluid cooler manifold and secure with clip. 4.Connect gearbox fluid cooler pipes to gearbox fluid cooler. 5.Remove container from below gearbox fluid cooler. 6.Connect battery earth lead. 7.Fill cooling system. + COOLING SYSTEM - V8, ADJUSTMENTS, Coolant - drain, flush & refill. 8.Check and top up gearbox fluid. + MAINTENANCE, PROCEDURES, Gearbox fluid - V8. 9.Check gearbox fluid cooler and connections for leaks.
AUTOMATIC TRANSMISSION - ZF 5HP24 REPAIRS 44-2-21 Thermostat - fluid cooler $% 44.24.17 Remove 1.Drain cooling system + COOLING SYSTEM - V8, ADJUSTMENTS, Coolant - drain, flush & refill. 2.Release clips and disconnect 3 coolant hoses from the transmission fluid cooler. CAUTION: Always fit plugs to open connections to prevent contamination. 3.Remove Torx screw securing gearbox fluid cooler to cooling pack and remove the gearbox fluid cooler. 4.Remove and discard gearbox fluid cooler O rings. Refit 1.Clean hose connections. 2.Fit new gearbox fluid cooler O rings. 3.Fit gearbox fluid cooler to cooling pack and secure with screw. 4.Connect coolant hoses to gearbox fluid cooler and secure with clips. 5.Fill cooling system. + COOLING SYSTEM - V8, ADJUSTMENTS, Coolant - drain, flush & refill. Valve body assembly $% 44.40.01 Remove 1.Remove gearbox fluid filter. + AUTOMATIC TRANSMISSION - ZF 5HP24, REPAIRS, Filter - fluid. 2.Disconnect multiplug from gearbox. 3.Remove retaining clip from multiplug and release plug from gearbox casing. 4.Remove 2 Torx bolts securing speed sensor clamps, remove clamps and sensors. M44 1937 M44 1813
AUTOMATIC TRANSMISSION - ZF 5HP24 44-2-22 REPAIRS 5.Evenly and progressively loosen and remove 22 large shouldered Torx bolts from valve block. 6.Remove valve block assembly. Refit 1.Clean valve block and mating faces. 2.With assistance fit valve block and multiplug, ensure selector fork locates on peg. 3.Evenly and progressively fit and tighten 22 valve block Torx bolts to 10 Nm (7 lbf.ft) 4.Fit gearbox multiplug retaining clip. 5.Connect multiplug to gearbox connector. 6.Fit speed sensor to valve block, position clamp and tighten Torx bolt to 10 Nm (7 lbf.ft). 7.Fit gearbox fluid filter. + AUTOMATIC TRANSMISSION - ZF 5HP24, REPAIRS, Filter - fluid.
DRIVESHAFTS REPAIRS 47-1 DRIV ESHAFTS REPAIRS Drive shaft - front - LH $% 47.10.01 Remove 1.Raise front of vehicle. WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands. 2.Remove road wheel. 3.Release drive shaft hub nut stake. 4.With an assistant applying brakes, remove and discard drive shaft hub nut. 5.Remove brake disc. + BRAKES, REPAIRS, Brake disc - front. 6.Release ABS sensor lead from clip. 7.Release sensor lead from damper, remove Allen screw and release ABS sensor from hub.8.Remove and discard nut securing track rod ball joint to steering arm. 9.Fit an M14 nut to ball pin, flush with end of pin. 10.Using LRT-57-036 separate ball pin from steering arm. Remove M14 nut and release ball pin from steering arm. CAUTION: Ensure ball joint seal is not damaged. A damaged seal will lead to premature failure of the joint. 11.Remove nut securing height sensor link to lower arm and release link. CAUTION: Use an open ended spanner on flats provided to prevent ball joint rotating. 12.Loosen bolt securing lower arm to subframe one quarter of a turn. 13.Remove nut securing lower arm ball joint to hub. M47 0412 M54 0179 LRT-57-036
DRIVESHAFTS 47-2 REPAIRS 14.Using LRT-54-027 release lower arm ball joint and disconnect lower arm from hub. CAUTION: Ensure ball joint seal is not damaged. A damaged seal will lead to premature failure of the joint. 15.Loosen bolt securing tie rod to subframe one quarter of a turn. 16.Remove nut securing tie rod to ball joint.17.Using LRT-54-027 release tie rod from ball joint CAUTION: Ensure ball joint seal is not damaged. A damaged seal will lead to premature failure of the joint. 18.Fit centre screw LRT-60-030/3 to LRT-60-030/ 1 and fit to hub with spacer LRT-60-030/2. Secure with nuts LRT-60-030/5. 19.Tighten centre screw to press drive shaft from flange. 20.Remove tools. 21.Position container to collect oil spillage. M60 0789LRT -54-027M60 0787 LRT -54-027
DRIVESHAFTS REPAIRS 47-3 22.Fit LRT-54-026 to drive shaft inboard joint. 23.Using levers, release drive shaft from differential. 24.Release drive shaft from hub. 25.Remove drive shaft assembly, keep drive shaft horizontal to avoid damaging differential oil seal. 26.Remove and discard drive shaft circlip. Refit 1.Clean end of drive shaft and location in differential. 2.Fit new circlip to drive shaft. 3.Lubricate oil seal lip with clean differential oil. + CAPACITIES, FLUIDS, LUBRICANTS AND SEALANTS, Lubrication. 4.Fit drive shaft ensuring circlip is fully engaged. CAUTION: Pull the drive shaft to ensure the circlip is fully engaged and retains the shaft. 5.Clean drive shaft and flange splines. 6.Lightly lubricate splines and oil seal running surface. + CAPACITIES, FLUIDS, LUBRICANTS AND SEALANTS, Lubrication. 7.Locate drive shaft in hub.8.Fit LRT-60-030/4 to drive shaft. 9.Fit LRT-60-030/1 with spacer LRT-60-030/2 and secure with nuts LRT-60-030/5. 10.Fit nut to LRT-60-030/4 and tighten nut to pull drive shaft into drive flange. 11.Remove tools. 12.Clean ball joint tapers and taper seats. 13.Connect tie rod to ball joint, fit nut and tighten to 80 Nm (59 lbf.ft). 14.Connect lower arm ball joint to hub, fit nut and tighten to 80 Nm (59 lbf.ft). 15.Connect height sensor link to lower arm, fit nut and tighten to 8 Nm (6 lbf.ft). CAUTION: Ensure height sensor arm is pointing outwards. 16.Connect ball joint to steering arm, fit new nut and tighten to 80 Nm (59 lbf.ft). 17.Clean ABS sensor, smear sensor with an anti- seize grease and fit sensor to hub. + CAPACITIES, FLUIDS, LUBRICANTS AND SEALANTS, Lubrication. 18.Fit Allen screw securing ABS sensor and tighten to 8 Nm (6 lbf.ft). 19.Secure sensor lead to damper. 20.Fit front brake disc. + BRAKES, REPAIRS, Brake disc - front. 21.Fit new hub nut and tighten to 420 Nm (311 lbf.ft). 22.Stake nut to shaft. 23.Fit road wheel and tighten nuts to 140 Nm (103 lbf.ft). 24.Remove stands and lower vehicle. 25.Tighten new bolt securing lower arm to subframe to 165 Nm (121 lbf.ft), plus a further 90°. M47 0414 LRT-54-026