Land Rover Range Rover Classic Workshop 1995 Rover Manual

							44AUTOMATIC GEARBOX
4
REPAIR INHIBITOR SWITCH
Service repair no - 44.15.19
Remove
1.Site vehicle on ramp. Disconnect battery
negative lead.
2.Disconnect inhibitor lead.
3.Remove bolt and spring washer.
4.Remove retaining plate.
5.Remove inhibitor switch.
Refit
6.Fit new O ring seal to inhibitor switch.
7.Fit switch and secure with retaining plate, spring
washer and bolt.
8.Connect inhibitor lead.
9.Reconnect battery negative lead.SELECTOR SHAFT OIL SEAL
Service repair no - 44.15.34
1.Site vehicle on ramp. Disconnect battery
negative lead.
2.Remove gear change lever.
3.Remove oil seal.
4.Coat new oil seal with light grease. Fit seal using
selector shaft oil seal replacer LST114.
5.Refit gearchange lever.
6.Fit nut. Tighten to
25 Nm. 
						

							ZF
5
REPAIR OIL SUMP GASKET
Service repair no - 44.24.05
1.Site vehicle on ramp. Disconnect battery
negative lead.
2.Drain gearbox oil. Remove oil level tube.
3.Remove six retaining plates and bolts.
4.Remove sump, discard gasket.
5.Inspect sump for damage. Replace if necessary.
6.Fit new gasket to sump.
7.Refit sump. Fit six retaining plates tighten screws
to
10Nm.
8.Reconnect oil filler level tube. Tighten to70Nm.
Fit sump plug with new seal. Tighten to10Nm.
9.Reconnect battery negative lead.
10.Add correct oil through filler/level tube.
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended Lubricants and
Fluids
11.Ensure vehicle is on level ground with park
brake applied. Check oil level with engine at idle,
neutral selected after selecting each gear.
NOTE: If leak persists after fitting existing
oil pan - fit new oil pan.KICKDOWN CABLE LEAK
Service repair no - 44.15.01
Remove
1.Site vehicle on ramp. Disconnect battery
negative lead.
2.Disconnect kickdown cable from engine.
3.Drain gearbox oil. Remove front exhaust
assembly and chassis cross member.
4.Remove oil level tube.
5.Remove six retaining plates and bolts.
6.Remove sump, discard gasket.
7.Loosen three bolts, remove oil screen.
8.Loosen thirteen remaining bolts, remove control
unit.
9.Locate selector cam, remove nipple, holding
kickdown cable from seat. 
						

							44AUTOMATIC GEARBOX
6
REPAIR
10.Using kickdown cable remover LST112, remove
cable and its housing from casing and discard.
Refit
11.Fit new cable and new O ring into casing.
12.Spring load cam by turning once before fitting.
Fit nipple into cam seat.13.Fit control unit after cleaning face with a lint free
rag. Ensure selector shaft locates into gear shift
fork. Fit thirteen bolts loosely.
14.Place selector linkage setting gauge LST109 in
position, gently press control unit in direction
shown. Tighten all thirteen bolts to
8Nm.
15.Remove setting gauge. Fit oil screen, tighten
fixings to
8Nm.
16.Refit sump with new gasket.
17.Refit six retaining plates tighten screws to
8Nm.
18.Reconnect oil filler tube. Tighten to70Nm.Fit
sump plug with new seal. Tighten to
10Nm.
19.Fit chassis cross member
20.Fit front exhaust assembly
21.Reconnect battery negative lead.
22.Add correct quantity and grade oil to gearbox.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
23.Connect kickdown cable to engine.
Adjust
24.Adjust cable sheath to achieve a crimp gap of
0.25 to 1.25 mm.
25.Hold cable sheath while tightening locknuts.
26.Ensuring vehicle is on level ground with park
brake applied. Check oil level with engine at idle
with neutral selected, after selecting each gear. 
						

							ZF
7
REPAIR EXTENSION HOUSING
Service repair no - 44.20.18
1.Remove transfer box.
See TRANSFER
GEARBOX, Repair, Borg Warner Transfer
Gearbox
2.Remove transfer gear selector.
3.Loosen nine bolts holding extension housing.
4.Remove extension housing, discard gasket.
5.Place extension housing on bench, remove oil
seal.
6.Ensure that all surfaces are clean and case is
free from damage.
7.If fitting new case, fit two dowels to case.
8.Fit a new gasket and oil seal using rear oil seal
replacer LST108.
9.Fit extension case to gearbox, ensure oil seal is
not damaged by extension shaft.
10.Fit and tighten nine bolts to
23 Nm.
11.Refit transfer gear selector.
12.Tighten three bolts to
25 Nm.
13.Refit transfer box.OIL SCREEN
Service repair no - 44.24.07
1.Site vehicle on ramp. Disconnect battery
negative lead.
2.Drain gearbox oil.
3.Discard sump plug seal.
4.Remove level tube from sump.
5.Remove six retaining plates and bolts.
6.Remove sump, discard gasket.
7.Loosen three screws from oil screen.
8.Remove oil screen, discard O rings.
9.Separate oil screen from suction tube, discard
O ring and oil screen.
10.Fit two new O rings to oil screen.
11.Fit suction tube to oil screen.
12.Fit oil screen to control unit, tighten three bolts to
8 Nm. 
						

							44AUTOMATIC GEARBOX
8
REPAIR 13.Refit sump using a new gasket.
14.Secure using six retaining plates and bolts.
Tighten to
8Nm.
15.Reconnect oil level/filler tube. Tighten to70 Nm.
16.Fit sump plug using a new seal. Tighten to10
Nm.
17.Connect battery lead.
18.Add correct oil to gearbox.
See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
Recommended Lubricants and Fluids
19.Ensuring vehicle is on level ground with park
brake applied, check oil level with engine at idle,
neutral selected, after selecting each gear.
CONTROL UNIT
1.Site vehicle on ramp. Disconnect battery
negative lead.
2.Drain gearbox oil into a container.
3.Discard sump plug seal.
4.Remove oil level tube from sump.
5.Remove six retaining plates and bolts.
6.Remove sump, discard gasket.
7.Loosen three bolts and remove oil screen.
8.Loosen remaining thirteen bolts retaining control
unit. 
						

							ZF
9
REPAIR
9.Clean surfaces using a lint-free rag. Ensure no
damage has occurred to mounting face of case.
10.Fit control unit ensuring selector shaft locates
into gear shift fork. Loosely fit thirteen bolts.11.Place selector linkage setting gauge LST109 in
position, gently press control unit against tool.
Tighten to
8Nm.
12.Remove setting gauge. Fit oil screen. Tighten to
8Nm.
13.Refit sump using a new gasket.
14.Secure with six retaining plates and bolts.
Tighten to
8 Nm.
15.Reconnect oil level tube. Tighten to70 Nm.
16.Fit sump plug with new seal. Tighten to10 Nm.
17.Reconnect battery negative lead.
18.Add correct quantity and grade of oil to gearbox.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
19.Ensure vehicle is on level ground with park
brake applied. Check oil level with engine at idle,
neutral selected, after selecting each gear. 
						

							44AUTOMATIC GEARBOX
10
REPAIR OIL INLET SEALING RINGS
Service repair no - 44.20.13
1.Site vehicle on ramp. Disconnect battery
negative lead.
2.Drain gearbox oil into a container.
3.Discard sump plug seal.
4.Remove oil level tube from sump.
5.Remove six retaining plates and bolts.
6.Remove sump, discard gasket.
7.Loosen three bolts and remove oil screen.
8.Loosen remaining thirteen bolts retaining control
unit.
9.Clean surfaces using a lint-free rag. Ensure no
damage has occurred to mounting face of case.
10.Remove eight circlips and springs from gearbox.
11.Using LST 113 remove eight oil seals.
12.Clean orifices, check for damage.
NOTE: If damage has occurred replace
box.
See ZF Auto with Borg Warner
Transfer Gearbox
13.Using LST 113 fit new seals.
14.Fit eight compression springs, four short ones at
front and four long ones at rear.
15.Fit eight circlips to retain compression springs.
16.Fit control unit locating selector shaft into gear
shift fork. Fit thirteen bolts loosely.
17.Place setting gauge LST 109 in position. Press
control unit against tool, tighten thirteen bolts to
8Nm. 
						

							ZF
11
REPAIR 18.Remove setting gauge. Fit oil screen, tighten
fixings to
8 Nm.
19.Refit oil pan with new gasket.
20.Secure with six retaining plates and bolt.
Tighten to
8 Nm.
21.Reconnect oil level tube. Tighten to70 Nm.
22.Fit sump plug with new seal. Tighten to10 Nm.
23.Reconnect battery negative lead.
24.Add correct quantity and grade of oil to gearbox.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
25.Ensure vehicle is on level ground with park
brake applied. Check oil level with engine at idle,
neutral selected, after selecting each gear.MANUAL VALVE OPERATING MECHANISM
Service repair no - 44.40.01
1.Site vehicle on ramp. Disconnect battery
negative lead.
2.Drain gearbox oil into a container. Discard sump
plug seal.
3.Remove oil level tube from sump.
4.Remove six retaining plates and bolts.
5.Remove sump, discard gasket.
6.Loosen three bolts and remove oil screen.
7.Loosen remaining thirteen bolts retaining control
unit. 
						

							44AUTOMATIC GEARBOX
12
REPAIR
8.Locate selector cam, remove kickdown cable
nipple from its seat.
9.Remove gear change lever.
10.Drift out roll pin from selector shaft, discard pin.
11.Remove selector shaft from box, note position of
detent plate for reassembly.
12.Remove connecting rod with detent plate,
accelerator cam, and spring. Remove and
discard oil seal.
13.Check all parts for wear or damage, replace as
necessary.
14.Using LST114, fit oil seal use petroleum jelly to
aid assembly.
15.Fit connecting rod to detent plate, locate in box
by pushing selector shaft through from outside of
casing.
16.Fit accelerator cam with spring.
17.Fit assembly into box and secure by pushing
selector shaft through.
18.Align hole in selector shaft with hole in detent
plate. Secure with a new roll pin.
19.Spring load cam by turning once. Fit kickdown
cable nipple into cam seat.
20.Fit control unit ensuring selector shaft locates
into gear shift fork. Fit thirteen bolts loosely.
21.Position setting gauge LST 109. Press control
unit against tool. Tighten thirteen bolts to
8 Nm.
22.Remove setting gauge, fit oil screen, tighten
fixings to
8 Nm.
23.Refit oil pan with new gasket.
24.Secure with six retaining plates and bolt.
Tighten to
8 Nm.
25.Reconnect oil level tube. Tighten to70 Nm.
26.Fit sump plug with new seal. Tighten to10 Nm.
27.Reconnect battery negative lead.
28.Add correct quantity and grade of oil to gearbox.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
29.Ensure vehicle is on level ground with park
brake applied. Check oil level with engine at idle,
neutral selected, after selecting each gear. 
						

							ZF
13
REPAIR GOVERNOR HOUSING
Service repair no - 44.22.01
Remove
1.Remove transfer box.
See TRANSFER
GEARBOX, Repair, Borg Warner Transfer
Gearbox
2.Remove transfer gear selector housing.
3.Loosen nine bolts holding extension housing.
4.Remove extension housing ensuring that seal is
not damaged, discard gasket.
5.Remove extension shaft and retaining bolt with
O ring. If Tdi vehicle, remove spacer.
6.Remove governor assembly with parking wheel.
7.Remove two screws holding governor housing.
8.Remove governor housing complete and
discard.
9.Inspect governor hub and parking wheel for
damage.Refit
10.Fit new governor housing complete to governor
hub and parking wheel. Tighten to
10 Nm.
11.Push governor assembly with parking wheel
onto output shaft until fully seated.
NOTE: Apply petroleum jelly to O ring.
Ensure seal rings are snapped together
and seated.
12.Fit extension shaft, with spacer if Tdi, apply
Loctite 270 to retaining bolt. Using a new O
ring. Tighten to
42 Nm.
13.Fit new gasket to rear of gearbox. Fit extension
housing, avoid damage to seal.
14.Tighten nine extension housing nine bolts to
23
Nm.
15.Fit transfer gear selector housing.
16.Tighten three bolts to
25Nm.
17.Refit transfer box.