300Tdi Discovery
ZF
7
REPAIR
Accessories removal/fitting
If fitting a replacement transmission assembly to the
vehicle, remove the following items from the existing
assembly and fit to the replacement.
CAUTION: It is important to remove the
spacer from the extension shaft and fit
onto the replacement unit.
50. Breather pipe union and washers from main
gearbox.
51. Breather pipe, union and washers from transfer
gearbox.
52. Main gearbox selector lever.
53. RH mounting bracket assembly.
54. Oil cooler pipe unions.
55. Fit blanks to all apertures where unions have
been removed and blank off pipe ends.
Refit
1. Fit transmission to cradle and hoist.
2. Locate hoist under vehicle and remove torque
convertor retaining strap.
3. Ensure low range gear is engaged.
4. Apply approved sealant to bell housing face.
5. Carefully raise assembly, align bell housing with
flywheel housing and bring mating faces
together.
6. Fit nuts and bolts to secure transmission to
engine.
7. Locate electrical wiring and breather pipes to
position.
8. Secure kick down cable clip to bell housing.
9. Raise hoist sufficiently to take weight.
10. Remove block and jack from engine sump.
11. Fit filler/dipstick tube to gearbox sump and
secure bracket to bell housing.
12. Apply Loctite to torque convertor bolts
13. Working through starter aperture refit the four
torque convertor to flexible drive securing bolts,
rotating crankshaft to gain access to bolt
locations.
14. Refit starter and heatshield.
15. Secure breather pipes and harness with ties.
16. Fit left hand mounting bracket assembly to
gearbox.
17. Raise transmission and support with a suitable
ramp [hoist] jack.
18. Remove two bolts securing transmission to
cradle, lower hoist and remove from under
vehicle.
19. Apply Loctite to above bolts and fit to transfer
gearbox input bearing support plate.
20. Fit chassis cross member.
21. Secure gearbox mounting brackets to chassis
cross member.
22. Remove ramp [hoist] jack.
23. Connect electrical leads to differential lock
switch.
24. Connect inhibitor switch multi-plug.
25. Connect selector cable to lever on side of
gearbox.
26. Connect oil cooler pipes to gearbox and secure
retaining bracket to gearbox sump.
27. Secure silencer to chassis and refit exhaust front
pipe.
28. Refit front propeller shaft to transfer gearbox.
29. Refit rear propeller shaft.
See PROPELLER
SHAFTS, Overhaul, Flexible Coupling
30. Connect speedometer cable to transfer gearbox.
31. Refill transfer gearbox with correct grade of
lubricating oil.
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information,
Recommended Lubricants and Fluids
32. Lower ramp [hoist] to ground level.
33. Reconnect turbo-charger hose to inter-cooler.
34. Reconnect top hose to radiator.
35. Refill cooling system with correct mixture of
coolant.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
36. Reconnect kick down cable to fuel injection
pump.
37. Secure breather pipe clip to rear of cylinder
head.
38. Engage harness with clips along top of
bulkhead.
39. On left hand drive vehicles only, connect
multi-plug to top of brake fluid reservoir.
40. Refit insulation pad to rocker cover and inlet
manifold, secure with oil filler cap.
41. Refit gaiter and knob to transfer gear lever.
42. Select high range gear.
43. Reconnect battery terminals.
44. Refill main gearbox with correct grade of
lubricating oil.
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information,
Recommended Lubricants and Fluids
