Discovery II
AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS
44-31
40. Fit suitable strap to retain torque converter.
Refit
1. Clean gearbox to engine mating faces.
2. Remove torque converter retaining strap.
3. With assistance position gearbox to engine.
4. Fit but do not tighten six bolts securing gearbox
housing to engine.
5. Connect multiplug to gearbox and tighten
locking ring.
6. Connect multiplug to inhibitor switch.
7. If fitted: Connect and adjust differential lock
selector cable.
ADJUSTMENTS, Cable - selector -
differential lock - adjust.
8. Position selector lever to inhibitor switch and
tighten nut to 25 Nm (18 lbf.ft).
9. Position selector cable to gearbox and secure
with 'C' clip.
10. Clean oil pipe unions and fit new 'O' rings.
11. Position and tighten pipe unions to gearbox.
12. Position and tighten oil cooler pipe clamps.
13. Position and tighten oil cooler pipe clips to
engine sump and alternator bracket.
14. Position engine RH and LH rear mountings
and tighten bolts to 85 Nm (63 lbf.ft) and nuts to
85 Nm (63 lbf.ft).
15. Secure gearbox breather pipes to bulkhead
clip.
16. Up to 03 Model Year - If fitted: Connect 2
Lucars to differential lock warning lamp switch
and multiplugs to high/low ratio switch and
neutral sensor.
17. 03 Model Year onwards - If fitted: Connect
differential lock warning lamp switch multiplugs
to main harness.
18. Position cable tie and multiplug to transfer box
bracket.
19. Connect high/low ratio selector cable to
selector lever and secure with clevis pin.
20. Position high/low ratio selector cable to
abutment bracket and secure with 'C' clip.
21. Models fitted with high/low shift interlock
solenoid: Position interlock solenoid harness
to high/low shift cable, fit sleeve around cable
and harness.
22. Models fitted with high/low shift interlock
solenoid: Connect solenoid multiplug to main
harness and secure multiplug to bracket.
23. Position handbrake backplate and tighten bolts
to 75 Nm (55 lbf.ft).
24. Fit hand brake drum and tighten screw.
25. Remove bolts securing tool LRT-99-008A to
gearbox.
26. Rotate engine to align torque converter, fit new
bolts and tighten to 50 Nm (37 lbf.ft).
27. Fit rear propeller shaft.
28. Fit front propeller shaft.
29. Fill transfer gearbox with oil.
30. Fill automatic gearbox with oil.
31. Position intermediate silencer and secure to
mounting rubbers.
32. Clean silencer and tail pipe mating faces.
33. Position new gasket to tail pipe and tighten
nuts to 25 Nm (18 lbf.ft).
34. Fit exhaust front pipe.
SYSTEMS - Td5, REPAIRS, Pipe - front.
35. Fit bolt securing closing plate to gearbox
housing and tighten to 7 Nm (5.2 lbf.ft).
36. Fit upper bolts securing gearbox housing to
engine and tighten to 50 Nm (37 lbf.ft).
37. Fit starter motor.
REPAIRS, Starter motor - diesel.
38. Tighten remaining gearbox housing to engine
bolts to 50 Nm (37 lbf.ft).
39. Connect battery earth lead.
40. Fit battery cover and secure with fixings.
41. Check and adjust selector cable.
