300Tdi Discovery
ZF
3
REPAIR
19. Disconnect rear propeller shaft to output flange,
and tie to one side.
20. Repeat instructions 18 and 19 on front propeller
shaft to main gearbox.
21. Remove bolts retaining silencer front and rear
securing brackets and tie silencer to one side.
22. Disconnect oil cooler feed and return pipes from
bottom and side of main gearbox.
23. Release cooler pipes from clamp at engine sump
and remove distance piece.
24. Blank pipe ends and unions.
25. Move oil cooler pipes clear of transmission and
tie aside.
26. Disconnect selector cable from operating lever.
27. Disconnect inhibitor switch at multiplug.
28. Attach adaptor plate to hoist.
29. Remove two bolts from transfer gearbox rear
cover.
30. Raise hoist to align adaptor plate with transfer
gearbox and transmission. Secure to transfer
gearbox at rear cover with two bolts removed.
31. Adjust hoist to take weight of transmission.
32. Remove nuts and bolts securing right transfer
gearbox mounting bracket to chassis.
33. Repeat for the left mounting bracket. Removal of
these fixings will also free speedometer
transducer bracket
34. Remove right side mounting bracket to flexible
mounting rubber retaining nut.
35. Lower hoist until rear brake drum clears
passenger footwell. Check engine does not
crush any components while lowering.
36. Remove clip and clevis pin from park brake
lever.
37. Remove clip securing outer brake cable
38. The park brake cable is now free.
39. Disconnect leads from transfer gearbox
temperature sensor and differential lock warning
light switch.
40. Remove ties securing breather pipes to harness.
41. Remove bell housing access plate complete with
gasket.
42. Rotate engine, using crankshaft pulley, until two
access holes are visible in drive plate/ring gear
assembly through bell housing bottom cover
opening.
43. Identify an access hole and bolt hole to aid
reassembly.
44. Remove bolts securing drive plate to convertor
through access holes.
45. Rotate crankshaft half turn to access and
remove remaining bolts.
46. Disconnect oil dipstick tube at main gearbox.
47. Remove bolt at bell housing and detach dipstick
tube. Blank pipe end and union.
48. Position hoist jack channel under engine and
support using a wooden block.
49. Remove bell housing to engine securing bolts,
also detach harness bracket from bell housing.
50. Ease transmission rearwards to allow access to
secure torque converter in bell housing.
51. Lower hoist and complete removal of
transmission.
Refit
52. Ensure torque converter is retained in bell
housing.
53. Secure transmission to adaptor plate on lifting
hoist.
54. Raise hoist and locate transmission with engine.
55. Remove torque converter retainer.
56. Complete attachment of transmission to engine
and fit bell housing bolts. Fit the dipstick tube
bracket and harness bracket to their respective
bolts.
57. Complete refitting by reversing removal
procedure. Note the following important points.
58. Drive plate to torque converter bolts are to be
coated with Loctite 290 prior to assembly.
59. Refill transfer and main gearboxes with correct
grade oil.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
60. Check operation of parking brake and adjust as
necessary.
See SECTION 10, Maintenance,
Vehicle Interior
