Land Rover Range Rover Classic Workshop 1995 Rover Manual
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BORG WARNER 1 SPECIFICATIONS, TORQUE TORQUE VALUES NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are tightened to the correct torque. Nm Brake drum back plate to rear output housing 73........................................... Brake drum to drive flange 25......................................................................... Centre differential (front to rear) 60................................................................. Drive flanges to transfer gearbox 224.............................................................. Driven gear to centre differential 50................................................................ Front cover to rear cover - main case 40........................................................ Front output housing to main case 33............................................................. Gearbox mounting brackets to chassis 45...................................................... Mounting bracket to gearbox 102.................................................................... Neutral warning switch 47............................................................................... Oil drain plug 25.............................................................................................. Oil filler/level plug 25....................................................................................... Oil pump fixings 7.......................................................................................... Propeller shafts to drive flanges 46................................................................. Rear output housing to main case 40............................................................. Selector lever shaft 8..................................................................................... Selector fork operating arm 8......................................................................... Torque values below are for all screws and bolts used except for those that are specified otherwise. METRIC Nm M5 6...................................................................................................... M6 9...................................................................................................... M8 25..................................................................................................... M10 45................................................................................................... M12 90................................................................................................... M14 105.................................................................................................. M16 180.................................................................................................. UNC / UNF 1/4 9...................................................................................................... 5/16 24................................................................................................... 3/8 39..................................................................................................... 7/16 78................................................................................................... 1/2 90..................................................................................................... 5/8 136....................................................................................................
BORG WARNER 1 SERVICE TOOLS ADAPTER PLATE TRANSFER BOX Adaptor plate for removing Borg Warner transfer gearbox. This can be manufactured locally to drawing shown. Material: Steel BS 1449 Grade 4 or 14. Drill holes marked * to fit hoist used.
41TRANSFER GEARBOX 2 SERVICE TOOLS LRT-41-010 Oil seal replacer. LST.550-6
ZF 1 DESCRIPTION AND OPERATION DESCRIPTION The automatic transmission is specially tailored version of the ZF4 HP22, used by many manufacturers of high performance vehicles. A three element torque converter delivers the power to a four speed epicyclic transmission. First, second and third gears are reduction ratios but fourth is an overdrive gear for high speed cruising. A direct drive clutch, integral with the torque converter operates to engage fourth gear. The gear selector has seven positions as follows: P = Park provides a mechanical lock on the output shaft. R = Reverse gear. N = Neutral. D = Provides a 1st gear start and automatic shifts 1-2-3-4-3-2-1. 3 = Provides a 1st gear start and automatic shifts 1-2-3-2-1. 2 = Provides a 1st gear start and automatic shifts 1-2-1 or 3-2-1. 1 = Provides a 1st gear start with no up shifts, or 3-2-1. All automatic shifts are automatically controlled by the valve block and an hydraulic governor driven by the output shaft.
44AUTOMATIC GEARBOX 2 DESCRIPTION AND OPERATION Power flow 1st gear D selected With D selected 1st gear engaged, clutches 4 and 11 are operative. The front planet gear carrier of gear set 9 is locked against the housing through freewheel 15 when the engine is pulling but freewheels when the vehicle is coasting. Epicyclic gear set 10 rotates as a solid unit with the front planet gear carrier. In selector position 1 with 1st gear engaged, clutch 8 operates to prevent the loss of drive on the overrun through freewheel 15, to provide engine braking. 2nd gear D selected Clutches 4, 6, 7 and 11 are engaged. Freewheel 15 overruns, the hollow shaft with the sun wheel of epicyclic gear set 9 is locked. Epicyclic gear set 10 also rotates as a solid unit.
ZF 3 DESCRIPTION AND OPERATION 3rd gear D selected Clutches 4, 5, 7 and 11 are engaged. Freewheel 15 and 16 are overrun. Epicyclic gear set 9 and 10 rotate as a solid unit at a ratio of 1:1. 4th gear D selected Clutches 4, 5, 7 and 12 are engaged. Freewheel 14, 15 and 16 are overrun. Epicyclic gear set 9 rotates as a solid unit. The hollow shaft with the sun wheel of epicyclic gear set 10 is locked. Above a predetermined road speed, clutch 2 locks the gearbox power input direct to the engine, by-passing the torque converter. 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.
ZF 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 ñ 0.3 bar, 150 ñ 5 lbf/in 2.................................................................... Idle pressure 6.9 ñ 0.3 bar, 100 ñ 5 lbf/in2at 665 to 735 rev/min. .................................................................... To fit pressure gauge Service tools: See Service tools, Automatic Gearbox 0 to 20 bar, 0 to 300 lbf/in2Pressure gauge. Flexible hose adaptor. 1.Site vehicle on a ramp [hoist]. 2.From under gearbox, remove socket head plug (located 10cm from oil pipe) Fit hose adaptor LST502-1. 3.Fit hose to adaptor. 4.Fit gauge 18G502A to hose and route into vehicle, ensuring hose is clear of rotating parts and exhaust pipes. 5.Carry out road test.See Road Test Procedure Remove pressure gauge 6.Reverse removal procedure.
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 10 bar, 150lbf/in 2 CHECK 2 Check 1st to 2nd upshift speed and quality. Pressure should fall to 8.2 bar, 120 lbf/in 2. CHECK 3 Check 2nd-3rd upshift speed and quality. Pressure should fall to 6.8 bar, 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. END OF ROADTEST 1ROADTEST 2 CHECKS = 9-10-11 D SELECTED FROM REST FULL THROTTLE START CHECK 9 Check 1st-2nd upshift speed and quality. CHECK 10 Check 2nd 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. END OF ROADTEST 2
ZF 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 2nd upshift speed and quality. CHECK 13 Check 2nd 3rd upshift speed and quality. CHECK 14 Check 3rd 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 500rpm 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 ILLUSTRATED 1. Gearbox assembly 2. Inhibitor switch assembly 3. Control unit assembly 4. Filter and sump assembly