Land Rover Range Rover Classic Workshop 1995 Rover Manual
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44AUTOMATIC GEARBOX 14 REPAIR GOVERNOR HUB Service repair no - 44.22.04 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. 6.Remove governor assembly with parking wheel. 7.Remove two screws holding governor housing. 8.Remove two bolts, remove parking wheel. Discard governor hub. 9.Remove security clip and counter-weight. 10.Remove O ring from output shaft and discard. 11.Remove three seal rings from F clutch housing shaft. 12.Inspect all parts for damage or wear, replace if necessary. Refit 13.Fit counterweight and security clip into new governor hub.14.Secure governor housing to governor hub. Tighten to 10Nm. 15.Fit parking wheel to governor hub. Tighten to10 Nm. 16.Fit three new seal rings onto F clutch housing shaft, fit O ring onto output shaft. NOTE: To aid fitting of O ring apply petroleum jelly. 17.Push governor assembly and parking wheel onto output shaft until seated. NOTE: Apply petroleum jelly to O ring. Ensure seal rings are snapped together and seated. 18.Fit new gasket to rear of gearbox. Fit extension housing, avoid damaging seal. 19.Fit extension shaft, apply Loctite 270 to retaining bolt. Using a new O ring. Tighten to 42 Nm. 20.Tighten nine extension housing nine bolts to23 Nm. 21.Fit transfer gear selector housing, tighten three bolts to 25 Nm. 22.Refit transfer box.
ZF 15 REPAIR PARKING PAWL MECHANISM Service repair no - 44.28.07 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 guide plate bolt. 8.Remove plate and guide plate from gearbox case. 9.Remove pin, pawl and spring. CAUTION: When removing assembly. Avoid damaging parts which could weaken spring tension. 10.Inspect all parts for wear or damage. Replace if necessary. Refit 11.Fit pin and leg spring, locate spring correctly. 12.Fit pawl to pin. Locate spring leg into hole in pawl to create tension in spring. 13.Fit plate and guide plate. Tighten to 10 Nm. 14.Push governor assembly with parking wheel onto output shaft until seated. NOTE: Apply petroleum jelly to O ring. Ensure seal rings are snapped together and seated. 15.Fit new gasket to rear of gearbox. Fit extension housing, taking care not to damage seal or assembly. 16.Fit extension shaft with spacer if Tdi and retaining bolt with new O ring. 17.Fit extension housing, tighten nine bolts to 23Nm. 18.Fit transfer gear selector housing, tighten three bolts to 25 Nm. 19.Refit transfer box.
44AUTOMATIC GEARBOX 16 REPAIR REPLACING TORQUE CONVERTER 1.Remove gearbox and transfer box assembly. See ZF Auto with Borg Warner Transfer Gearbox 2.Place gearbox on bench. Remove torque converter using torque converter handles 18G1501, taking care not to damage torque converter/oil pump housing oil seal. 3.Fit new torque converter using torque converter handles 18G1501. Check dimension from converter fixing boss to converter housing face is 50 mm. This shows converter is correctly seated in housing. 4.Refit gearbox and transfer box assembly. See ZF Auto with Borg Warner Transfer Gearbox ELIMINATING LEAKS ON PUMP HOUSING 1.Remove gearbox and transfer box assembly. See ZF Auto with Borg Warner Transfer Gearbox 2.Place gearbox on bench. Remove torque converter using torque converter handles 18G1501, taking care not to damage torque converter/oil pump housing oil seal. 3.Remove twelve hexagonal bolts (inner ring pattern). 4.Remove bell housing and pump assembly, discard gasket. 5.Remove eight hexagonal bolts on rear of pump.
ZF 17 REPAIR 6.Screw in two bolts, diagonally opposite each other. Tap lightly using a soft headed mallet to remove pump assembly from intermediate plate. 7.Remove shaft sealing ring and O ring from pump housing and discard. 8.Using oil seal replacer LST108 fit shaft seal ring into pump housing. 9.Fit O ring onto circumference of pump housing. 10.Align dowel with hole in intermediate plate and press pump housing home.11.Fit pump housing to intermediate plate, tighten eight bolts to 10 Nm. 12.Place bell housing and intermediate plate assembly on bench, front face up. Using oil pump rotation sleeve LST111, check that pump gears rotate freely. 13.Before fitting intermediate plate and bell housing assembly,check that thrust washer and axial cage are seated on A clutch housing. 14.Place gasket and disc washer onto bell housing and intermediate plate assembly using Petroleum Jelly. 15.Fit bell housing and intermediate plate assembly to gearcase. Tighten twelve bolts to 46 Nm. 16.Place end float gauge LST111 onto pump housing and check that axial play is between 0.2-0.4 mm. Replace existing washer, situated at rear of intermediate plate, with a suitable washer to give required end float. 17.Refit torque converter into housing using torque converter handles 18G1501, checking that dimension from converter fixing bolt boss to converter housing face is 50 mm. This shows converter is properly seated in housing. 18.Refit gearbox/transfer box assembly. See ZF Auto with Borg Warner Transfer Gearbox
44AUTOMATIC GEARBOX 18 REPAIR ELIMINATING LEAKS BETWEEN GEARBOX HOUSING AND INTERMEDIATE PLATE 1.Remove gearbox and transfer box assembly. See ZF Auto with Borg Warner Transfer Gearbox 2.Place gearbox on bench. Remove torque converter using torque converter handles 18G1501, taking care not to damage torque converter/oil pump housing oil seal. 3.Remove twelve hexagonal bolts (inner ring pattern). 4.Remove bell housing/intermediate plate assembly from gearbox case and discard gasket. 5.Place new gasket onto intermediate plate using Petroleum Jelly. 6.Before fitting bell housing assembly check that thrust washer and axial cage are seated on A clutch housing. 7.Fit bell housing assembly with disc washer to gearcase. Tighten twelve bolts to 46Nm. 8.Place end-float gauge LST111 onto pump housing and check that axial play is between 0.2-0.4 mm. Replace existing washer, situated at rear of intermediate plate, with a suitable washer to give required end-float. 9.Refit torque converter using torque converter handles 18G1501. Checking that dimension from converter fixing boss to converter housing case is 50mm. This dimension shows converter is properly seated. 10.Refit gearbox/transfer box assembly. See ZF Auto with Borg Warner Transfer Gearbox
ZF 19 REPAIR REPLACING BELLHOUSING Service repair no - 44.17.01 1.Remove gearbox and transfer box assembly. See ZF Auto with Borg Warner Transfer Gearbox 2.Place gearbox on bench. Remove torque converter using torque converter handles 18G1501, taking care not to damage torque converter/oil pump housing oil seal. 3.Remove eighteen hexagonal bolts. 4.Remove bell housing. 5.Fit new bell housing. 6.Secure bell housing, tighten eighteen bolts to 46 Nm. 7.Refit torque converter using torque converter handles 18G1501. Check that dimension from converter fixing boss to converter housing face is 50 mm. This dimension shows converter is properly seated in housing. 8.Refit gearbox/transfer assembly. See ZF Auto with Borg Warner Transfer Gearbox
44AUTOMATIC GEARBOX 20 REPAIR REPLACING PUMP Service repair no - 44.32.01 1.Remove gearbox and transfer box assembly. See ZF Auto with Borg Warner Transfer Gearbox 2.Place gearbox on bench. Remove torque converter using torque converter handles 18G1501, taking care not to damage torque converter/oil pump housing oil seal. 3.Remove twelve bolts (inner ring pattern). 4.Remove bell housing and pump assembly from gearbox case, discard gasket. 5.Remove eight bolts on rear of pump. 6.Screw in two bolts,diagonally opposite each other, tap lightly using a soft headed mallet to free pump assembly from intermediate plate. 7.Fit new pump assembly, aligning dowel with hole in intermediate plate, press pump housing home. 8.Secure pump housing to intermediate plate using eight hexagonal bolts and. Tighten to 10 Nm. 9.Place bell housing and intermediate plate assembly on bench, front face up. Using oil pump rotation sleeve LST111, check that pump gears rotate freely. 10.Before replacing intermediate plate/bell housing assembly check that thrust washer and axial cage are seated on A clutch housing. 11.Place new gasket and disc washer onto bell housing and intermediate plate assembly using a Petroleum Jelly. 12.Fit bell housing and intermediate plate assembly, tighten twelve bolts to 46 Nm.
ZF 21 REPAIR 13.Place end-float gauge LST111 onto pump housing and check that axial play is between 0.2-0.4 mm. Replace existing washer, situated at rear of intermediate plate, with suitable washer to give required end-float. NOTE: If damage is apparent to bolts they should be replaced.14.Refit torque converter into housing using torque converter handles 18G1501. Check dimension converter fixing boss to converter housing face is 50 mm. This shows converter is properly seated in housing. 15.Refit gearbox/transfer box assembly. See ZF Auto with Borg Warner Transfer Gearbox
44AUTOMATIC GEARBOX 22 REPAIR REPLACING INTERMEDIATE PLATE Service repair no - 44.20.11 1.Remove gearbox and transfer box assembly. See ZF Auto with Borg Warner Transfer Gearbox 2.Place gearbox on bench. Remove torque converter using torque converter handles 18G1501. 3.Remove twelve bolts (inner ring pattern). 4.Remove bell housing and pump assembly from gearbox case, discard gasket. 5.Remove eight bolts from rear of pump. 6.Screw in two bolts, diagonally opposite each other, tap pump to free pump assembly from intermediate plate. 7.Remove O ring from pump housing and discard. 8.Place bell housing and intermediate plate assembly on bench.
ZF 23 REPAIR 9.Remove six bolts and remove bell housing from intermediate plate assembly. 10.Remove four screw plugs and seal rings from intermediate plate, discard seal rings. 11.Remove oil cooler pipe adaptors, fit them into new intermediate plate. 12.Fit plugs and new seal rings into new intermediate plate. 13.Fit intermediate plate assembly onto bell housing. 14.Secure with six hexagonal bolts (outer ring pattern). Tighten to 46 Nm. 15.Place intermediate plate and bell housing assembly on bench, front face up. 16.Fit O ring onto circumference of pump housing. 17.Align dowel with hole in intermediate plate, press pump housing home. 18.Secure pump housing to intermediate plate, tighten eight bolts to 10Nm. 19.Place bell housing and intermediate plate assembly on bench. Using oil pump rotation sleeve LST111, check that pump gears rotate freely.20.Before replacing intermediate plate and bell housing assembly check that thrust washer and axial cage are seated on A clutch housing. 21.Place gasket and disc washer onto bell housing and intermediate plate assembly using Petroleum Jelly. 22.Fit bell housing and intermediate plate assembly onto gearcase, tighten twelve bolts to 46 Nm. 23.Place end-float gauge LST111 on pump housing and check that axial play is between 0,2-0,4 mm. Renew existing washer, at rear of intermediate plate, to give required end-float. 24.Refit torque converter into housing using torque converter handles 18G1501. Check dimension from converter fixing boss to converter housing face is 50 mm. This shows converter is properly seated in housing. 25.Refit gearbox/transfer box assembly. See ZF Auto with Borg Warner Transfer Gearbox