Land Rover Range Rover Classic Workshop 1995 Rover Manual
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ZF 5 FAULT DIAGNOSIS 1. Torque converter housing assembly 2. Gearbox pump and casing assembly 3. Governor and adaptor housing assembly
44AUTOMATIC GEARBOX 6 FAULT DIAGNOSIS 1. A Clutch assembly 2. B Clutch assembly
ZF 7 FAULT DIAGNOSIS 1. C, C and D Clutch assembly
44AUTOMATIC GEARBOX 8 FAULT DIAGNOSIS 1. Freewheel and fourth gear assembly
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 ú No drive FAULT - Continue with Symptom 3 ú Drives forward FAULT - Reverse gear interlock valve seized Select 1 ú No engine braking FAULT - Clutch brake 3 SYMPTOM 3 - No drive from rest with D selected Select 1 ú Vehicle drives FAULT - No 2 freewheel ú No drive Carry out main line pressure check ú Normal pressure FAULT - Clutch A ú No pressure FAULT - Blocked filter or pump failure ú Low pressure FAULT - Restricted filter or sticking primary regulator SYMPTOM 4 - Slip in all forward gears Carry out main line pressure check ú No pressure FAULT - Blocked filter or pump failure ú Low pressure FAULT - Restricted filter or sticking primary regulator ú Normal pressure FAULT - Clutch ASYMPTOM 5 - Harsh engagement N to D Check engine idle speed Carry out main line pressure check ú High pressure FAULT - Primary regulator stuck ú 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 ú High pressure FAULT - Continue with symptom 5 ú 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 ú High pressure FAULT - Continue with symptom 5 ú 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
ZF 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 (65 to 70 km/h). Carry out road test pressure check with gauge connected to torque converter. ú Normal pressure FAULT - Failed direct drive clutch ú 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 ú Normal pressure FAULT - Governor valve sticking ú 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 ú Normal pressure FAULT - Governor valve sticking ú 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 (45 km/h) 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
ZF 1 REPAIR ZF AUTO WITH BORG WARNER TRANSFER GEARBOX Remove Underbonnet WARNING: When using transmissions jack, follow equipment manufacturers instructions to ensure safe and effective use of equipment. 1.Place vehicle on ramp [hoist]. Check road wheels. 2.Disconnect battery negative lead. 3.Remove fan blade assembly. Note assembly has left hand thread. 4.Remove air intake hose from plenum chamber (V8i only). 5.Disconnect kickdown cable from throttle leakage. 6.Release gearbox breather pipes from the rear of the engine. 7.Remove gearbox dip stick. Inside Vehicle 8.Select low range, unscrew and remove transfer gearbox knob. 9.Remove cigar lighter. 10.Remove surround from gear selector panel. 11.Prise out wood veneer panel from centre console, and disconnect multiplugs from switches. 12.Remove the five fixings securing the centre console to the floor, and two clips at the front. 13.Disconnect multiplugs from window lift switch panel. 14.Disconnect multiplug to selector graphics panel and remove inset panel. 15.Disconnect electrical leads to cigar lighter. 16.Remove sound deadening trim from top of gearbox tunnel. 17.Remove retaining plate from transfer gearbox lever. Under Vehicle 18.Raise ramp [hoist].
44AUTOMATIC GEARBOX 2 REPAIR 19.Drain oil from main and transfer gearbox. Refit plugs. 20.Disconnect multiplugs to oxygen sensors and remove front exhaust sections. (V8i only) 21.Remove chassis cross member secured by eight nuts and bolts. (V8i only) 22.Release two clamps securing gearbox oil cooler pipes. 23.Place a suitable container below gearbox, disconnect oil cooler return pipes from gearbox. Plug open ends of pipe. 24.Remove dipstick tube from gearbox sump. 25.Mark propeller shaft and transfer gearbox flanges for reassembly. Disconnect propeller shafts at output flanges. Tie shafts to one side. 26.Disconnect multiplug from speed transducer. 27.Disconnect main gearbox selector cable and rod from left side of gearbox. Lay cable aside. 28.Disconnect inhibitor switch. 29.Remove transmission brake drum, remove four bolts securing back plate to transfer box and tie assembly aside complete with handbrake.Remove Transmission Assembly 30.Remove two bolts and remove cover plate from bottom of gearbox bell housing. 31.Rotate engine using crankshaft pulley until the access holes in the drive plate are visible. 32.Remove the bolts securing drive plate to torque converter. Mark one access hole and one bolt with an identification line for accurate reassembly. 33.Rotate crankshaft to remove all bolts. 34.Position transmission jack on rear output housing to support weight of transmission assembly. 35.Remove bolts and withdraw transfer gearbox and main gearbox mountings. 36.Remove bolts securing the chassis cross member, and using a suitable method of spreading the chassis remove the chassis cross member. (Tdi only) 37.Fit adaptor plate (See service tools) to transmission hoist, raise and position hoist under transfer gearbox mounting points. 38.Secure adaptor plate to gearbox using gearbox mounting bolts.
ZF 3 REPAIR 39.Remove transmission jack from transmission assembly. 40.Remove front exhaust pipe. (Tdi only) 41.Carefully lower transmission until top of transfer gearbox clears rear passenger footwell. 42.Position transmission jack under engine to support weight while bell housing bolts are removed. 43.Remove bell housing bolts, note that one bolt secures gearbox dip stick tube. 44.Withdraw transmission assembly from engine, ensuring torque converter is removed with gearbox. Refit 45.Refitting gearbox is reverse of removal instructions, noting following points. 46.Coat drive plate to torque converter bolts with Loctite 270. 47.Tighten all bolts to specified torque. See Specifications, torque, Torque Values 48.Fit new exhaust gaskets to torque. 49.Refill gearbox with correct grade and quantity of oil See LUBRICANTS, FLUIDS AND CAPACITIES, Information, Recommended fluid and lubricants