Automatic Transmission/Transaxle: Service and Repair
Gearbox - Convertor and Transfer GearboxNOTE: This procedure has been updated as per Land Rover technical bulletin 44/01/06/NAS
Service Repair No - 44.20.04/99
Remove
1. Release the four clips and remove the window lift switch finisher.
2. Remove the four securing screws and reposition the window switch pack from the center console.
3. Release the hand brake lever gaiter from the center console.
4. Remove the handbrake lever retaining clip and clevis pin.
5. Remove the battery cover.
6. Disconnect the battery ground lead.
7. Raise the vehicle on a suitable lift.
8. Where installed remove the undertray.
9. Remove the eight bolts securing the transmission cross member and remove the transmission cross member.
10. Remove the exhaust front pipe.
11. Remove the three nuts securing the intermediate pipe to the tail pipe.
12. Release and remove the intermediate pipe from the tail pipe and collect the gasket.
13. Remove the rear propeller shaft.
14. Remove the front propeller shaft.
15. Drain the automatic transmission oil.
16. Remove the bolt securing the transmission oil cooler pipe clip to the sump.
17. Remove the nut/bolt securing the transmission oil cooler pipe clamp and remove the clamp.
CAUTION: Always install clean plugs to open connections to prevent contamination.
18. Loosen and remove the oil cooler pipe unions from the transmission. Discard the 0-rings.
19. Release the transmission oil cooler pipes and tie aside.
20. Remove the starter motor.
21. Disconnect the electrical connector from the crankshaft sensor.
22. Remove the inspection plate from the transmission bell housing to gain access to the torque converter retaining bolts.
23. Rotate the crankshaft for access and remove the three bolts securing the drive plate to the torque converter. Discard the bolts.
24. Release and remove the clevis pin and 'C' clip securing the transfer transmission high/low selector cable to the transfer transmission high/low selector lever. Position the cable aside.
25. Disconnect the electrical connector from the reverse lamp switch.
26. If installed: Remove and discard the clevis pin securing the differential lock selector cable to the transfer box.
27. If installed: Loosen the locknuts securing the lock selector cable to the differential and release from the bracket.
28. Models installed with high/low shift interlock solenoid: Release the interlock solenoid connector and disconnect the connector from the main harness.
29. Models installed with high/low shift interlock solenoid: Remove the sleeve retaining rings and remove the sleeve from high/low select cable.
30. Disconnect the connector from the inhibitor switch.
31. Remove the nut securing the selector lever to the inhibitor switch and release the lever.
32. Rotate the locking ring anti-clockwise and disconnect the transmission connector.
33. Withdraw the handbrake cable from the body.
34. Release the transfer and transmission breather pipes from the bulkhead clip.
35. Position a suitable jack to support the transmission.
WARNING: Where the use of a transmission hoist is necessary, it is absolutely essential to follow the manufacturer's instructions to ensure safe and effective use of equipment.
36. Install special tool LRT-99-008A to the transmission jack and secure with bolts.
37. Remove the two bolts from the transfer box raise the transmission jack and install the bolts to secure LRT-99-008A under the transmission sump and transfer transmission.
38. Remove the two nuts securing the transmission mountings to the body.
39. Remove the eight bolts securing the mountings to the transmission.
40. Raise the transmission and remove the two transmission mounting bracket assemblies.
41. Lower the transmission sufficiently to access the top of the transmission.
CAUTION: To prevent damage to components, cushion the jack pad with a block of wood or hard rubber.
42. Position a second support jack under the engine using a block between the engine sump and jack to prevent damage to the sump.
43. Remove the transmission harness bracket retaining nut.
44. Remove the seven upper bolts securing the transmission to the engine.
45. Remove the remaining lower bolts securing the transmission to the engine.
CAUTION: Ensure the torque converter remains with the transmission.
46. With assistance carefully remove the transmission from the engine.
47. Install a strap to retain the torque converter.
Install
48. Clean the torque converter and drive plate mating faces.
NOTE: To prevent damage to the oil pump drive and torque converter ensure the set back tolerance from the drive plate mating face to the edge of the transmission housing is at a minimum of 24.8 mm (0.9 in).
49. Remove the torque converter retaining strap.
50. With assistance carefully install the transmission to the engine. Ensure engagement of the torque converter spigot and the transmission housing onto the dowels.
51. Install the bolts securing the transmission to the engine but do not tighten at this stage.
52. Rotate the engine to align the torque converter with the drive plate install new bolts and tighten to 50 Nm (37 ft. lbs.)
53. Tighten the bolts securing the transmission to the engine evenly to 45 Nm (33 ft. lbs.).
54. Install the harness clip to the stud and tighten the nut to 25 Nm (18 ft. lbs.).
55. Carefully raise the transmission to install the mountings.
56. Install the mounting bracket to the transmission and tighten bolts to 85 Nm (63 ft. lbs.).
57. Lower the transmission and tighten the nuts securing the mountings to the chassis to 48 Nm (35 ft. lbs).
58. Remove the jack supporting the engine.
59. Remove the two bolts securing LRT-99-008A to the transfer box.
60. Remove the support from the transmission.
61. Install the transfer box and automatic transmission breather pipes into the clip.
62. Insert the handbrake cable through the body to the handbrake lever.
63. Connect the connector to the transmission and tighten the locking ring.
64. Connect the inhibitor switch connector.
65. NOTE: Ensure the selector lever is correctly aligned and seated before the tightening of the nut.
Position the selector lever to the inhibitor switch and tighten the nut to 25 Nm.
66. Connect the connector to the reverse lamp switch.
67. If installed: Connect and secure the differential lock selector cable to the transfer box with the clevis pin.
68. Position the differential lock selector cable to the differential lock selector cable abutment bracket and tighten locknuts sufficiently to retain the cable.
69. Models installed with high/low shift interlock solenoid: Connect the solenoid connector to the main harness and secure the connector to the bracket.
70. Models installed with high/low shift interlock solenoid: Position the interlock solenoid harness to high/low shift cable install the sleeve around cable and harness and secure the sleeve.
71. Check and adjust the differential lock selector cable.
72. Connect the high/low shift cable to the abutment bracket and lever. Install the clevis pin and clip.
73. Install the inspection plate to bell housing and tighten the bolts to 7 Nm.
74. Connect the connector to the crankshaft position sensor.
75. Install the starter motor.
76. Release the oil cooler pipes.
77. Clean the oil cooler pipe unions and install new 0-rings.
78. CAUTION: Make sure the blanking plugs are removed before component is installed.
Align and install the cooler pipes to the transmission and securing clamps. Install the nut and bolts but do not tighten at this stage.
79. Tighten the oil cooler securing clamps nut and bolts to 10 Nm (7 ft. lbs).
80. Tighten the oil cooler unions to the transmission to 25 Nm (18 ft. lbs.).
81. Install the front propeller shaft.
82. Install the rear propeller shaft.
83. Using a new gasket connect the exhaust intermediate pipe to the tail pipe install the nuts and tighten to 25 Nm (18 ft. lbs.).
84. Install the exhaust front pipe.
85. Install the transmission cross member and tighten the eight securing bolts to 26 Nm (19 ft. lbs.).
86. Where necessary install the undertray.
87. Lower the vehicle on lift.
88. Connect the battery ground lead.
89. Install the battery cover.
90. Install and secure the handbrake cable to the handbrake lever.
91. Install and secure the hand brake lever gaiter to the center console.
92. Install the window switch pack to the center console.
93. Install and secure the window lift switch finisher to the trim casing.
94. Fill the automatic transmission with oil.