Automatic Transmission - Servicing: Removal & Installation Land Rover Discovery III

Replace Oil

1. Ensure that gearbox is cool. Apply handbrake and securely chock front and rear wheels.
2. Place a suitable container beneath gearbox.
3. Clean area around oil filler/level and drain plugs.
4. Remove oil drain plug, remove and discard sealing washer. (Scheme 130)
5. Allow oil to drain.
6. Fit new sealing washer to oil drain plug.
7. Fit automatic gearbox drain plug and tighten to 15 Nm (11 lbf.ft).
8. Remove oil filler/level plug, remove and discard sealing washer.
9. Fill gearbox with recommended oil to bottom of oil level/filler plug hole.
10. Select Park.
11. Ensure handbrake is applied.
12. Start engine and allow it to idle.
13. Apply footbrake.
14. Move selector lever through all gear positions, while continuing to fill the gearbox. Select Park.
15. With engine idling, continue filling gearbox until a 2 mm bead of oil runs from oil filler/level plug hole.
16. Fit new sealing washer to automatic gearbox filler/level plug, fit plug and tighten to 30 Nm (22 lbf.ft).
17. Stop engine.
18. Remove all traces of oil from gearbox casing.

Scheme 130

REMOVAL & INSTALLATION

Removal

1. Select position "D", remove gear selector knob and collect spacer. (Scheme 131) On 2003-2004 vehicles, remove both center console cup holders. On all vehicles, release selector panel, disconnect connector and remove panel. Release clips securing transfer box lever gaiter to center console and remove knob and gaiter.
2. On vehicles equipped with base trim, remove rubber mat from center console and remove cover plate from switch pack. (Scheme 132) Remove 4 screws securing switch pack to center console, disconnect connector and remove switch pack.
3. On vehicles with veneer trim, release veneered console cover and remove cigar lighter element. (Scheme 133) Disconnect connector from switch pack and remove veneered console cover. On all vehicles, remove 2 bolts securing forward edge of console to transmission tunnel. Release hand brake gaiter from console. (Scheme 134)
4. Remove clip and clevis pin securing cable to hand brake lever. Move hand brake to fully upward position. Release electric seat switches from console. Disconnect connector from switches and remove. Remove 2 bolts securing rear of console to transmission tunnel. Release center console from fascia. Disconnect connector and bulb from cigar lighter. (Scheme 135) Remove console.

Scheme 131

Scheme 132

Scheme 133

Scheme 134

Scheme 135

Installation

1. Install and secure cigar lighter body to console. Install lid to console and secure with screws. Install console. Connect connector and bulb to cigar lighter. Install center console to fascia. Install 2 bolts securing rear of console to transmission tunnel. Connect connector to seat switches. Install switches to console. Move hand brake to lowered position. Install cable to hand brake and secure with clevis pin and clip. Install hand brake gaiter to console. Install bolts securing forward edge of console to transmission tunnel.
2. On vehicles equipped with veneer trim, position veneered console cover and connect connector to switch pack. Install cigar lighter element and secure veneered console cover to console. On vehicles equipped with base trim, connect connector to switch pack. Install switch pack to console and secure with screws.
3. On vehicles equipped with base trim, install cover plate to switch pack, and rubber mat to console. On all vehicles, install transfer box gaiter and knob to lever. Secure transfer box gaiter to console. Connect connector to selector panel, install and secure panel to center console. Install spacer and knob to gear selector lever. On 2003-2004 vehicles, install both center console cup holders.

1. Remove center console. See «CENTER CONSOLE»(ref-169035-S12163504182004050600000). Raise and support vehicle. Loosen gear selector cable trunnion nut. (Scheme 136) Remove "C" clip and release gear selector cable from automatic transmission bracket. Lower vehicle. Remove sound deadener pad. (Scheme 137)
2. Remove 3 bolts securing gear selector lever bracket to tunnel and remove gear selector lever. (Scheme 138) Remove "C" clip securing outer cable to gear selector lever bracket. Remove locking ring securing inner cable to gear selector lever. Release inner cable from gear selector lever, release cable from grommet and remove cable from gear selector lever bracket.

Scheme 136

Scheme 137

Scheme 138

Position cable through grommet, align to bracket and secure with "C" clip. Install inner cable to gear selector lever and secure with locking ring. Feed gear selector cable through tunnel, align bracket, and install and tighten bolts. Install sound deadener pad. Install center console. Position gear selector cable through trunnion and automatic transmission bracket and secure with "C" clip. Adjust gear selector cable. See appropriate AUTOMATIC TRANSMISSION SERVICING article.

1. Remove knob from gear lever. (Scheme 131) Release selector panel from center console. Disconnect connector from selector panel and remove panel.
2. To install, position selector panel and connect connector. Secure selector panel to console. Install gear lever knob.

1. Remove valve body. See «VALVE BODY»(ref-169035-S12917945312004050600000). Remove nut securing selector shaft lever and release lever from gear selector switch shaft. see scheme 10 Remove 2 bolts securing gear selector switch to automatic transmission and remove switch.
2. Drift out and discard selector quadrant roll pin. (Scheme 139) Remove selector shaft. Remove selector quadrant and connecting rod. Remove oil seal taking care not to damage seal housing. Remove valve body assembly.

Scheme 139

Clean shaft and seal housing. Using a suitable adapter, install NEW seal. Position selector quadrant and connecting rod. Position selector shaft and secure to quadrant using NEW roll pin. Install valve body assembly.

1. Raise and support vehicle. Drain automatic transmission oil. Note transmission fluid pan bolt spacer positions for reinstallation. Remove 6 bolts and spacers securing transmission fluid pan to automatic transmission. Remove transmission fluid pan and discard gasket. (Scheme 140)
2. Remove Torx screw securing oil pick-up tube and remove tube. (Scheme 141) Remove 2 Torx screws securing filter to valve body and discard "O" rings.
3. Remove 2 bolts securing speed sensor harness bracket to valve body. (Scheme 142) Disconnect connector from automatic transmission housing. (Scheme 143) Using a 30 mm socket, remove nut securing connector block to automatic transmission housing. Remove 6 long bolts securing valve body to automatic transmission. (Scheme 144) Remove 5 short bolts securing valve body to automatic transmission. (Scheme 145) Release speed sensor and remove valve body. Remove and discard "O" ring from connector. (Scheme 146)

Scheme 140

Scheme 141

Scheme 142

Scheme 143

Scheme 144

Scheme 145

Scheme 146

1. Clean valve body and mating faces. Install NEW "O" ring to connector block. With assistance, position connector to automatic transmission housing and tighten nut. Align valve body to automatic transmission. Ensure manual valve is correctly located. Position speed sensor retaining bracket, and tighten screws to specification. See «TORQUE SPECIFICATIONS»(ref-169035-S33236039582004112400000) . Connect connector to automatic transmission.
2. Clean filter and pick-up tube using a lint free cloth. Install NEW "O" rings to filter. Position filter and tighten Torx screws to specification. See «TORQUE SPECIFICATIONS»(ref-169035-S33236039582004112400000) . Position oil pick-up tube and tighten Torx screw to specification. See «TORQUE SPECIFICATIONS»(ref-169035-S33236039582004112400000) .
3. Clean oil sump and mating face. Install new gasket to oil sump, position sump to automatic transmission. Position spacers and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-169035-S33236039582004112400000) . Fill automatic transmission with oil. Lower vehicle.

1. Remove valve body. See «VALVE BODY»(ref-169035-S12917945312004050600000). Disconnect connector from lock-up solenoid valve and release harness from clip. (Scheme 147) Remove Torx screw and retaining fork securing solenoid valve to valve body. Remove solenoid valve from valve body.
2. To install, clean lock-up solenoid valve with lint free cloth. Position solenoid valve in valve body. Position retaining fork and install and tighten Torx screw to specification. See «TORQUE SPECIFICATIONS»(ref-169035-S33236039582004112400000). Connect connector to lock-up solenoid valve and secure harness in clip. Install valve body assembly.

Scheme 147

1. Remove valve body. See «VALVE BODY»(ref-169035-S12917945312004050600000). Release and remove clip securing pressure regulator solenoid valve harness to valve body. Disconnect connector from pressure regulator solenoid valve. (Scheme 148) Remove 5 Torx screws securing pressure regulator to valve body and remove pressure regulator. (Scheme 149)
2. To install, clean pressure regulator and mating face with a lint free cloth. Position pressure regulator to valve body, install Torx screws and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-169035-S33236039582004112400000). Connect connector to pressure regulator solenoid valve, install clip and secure harness to valve body. Install valve body assembly.

Scheme 148

Scheme 149

1. Remove valve body. See «VALVE BODY»(ref-169035-S12917945312004050600000). To gain access to remove Torx screw and MV2 shift control solenoid valve, remove 3 Torx screws securing lock-up solenoid valve assembly to valve body and move solenoid aside. (Scheme 150)
2. Note their position and disconnect connectors from shift control solenoid valves MV1 and MV2. Remove Torx screw and retaining fork securing MV2 shift control solenoid valve to valve body. (Scheme 151) Note that the tag on the retaining fork faces towards the valve body. Remove shift control solenoid valves from valve body.

Scheme 150

Scheme 151

Clean MV2 shift control solenoid valve with lint free cloth. Position MV2 shift control solenoid valve to valve body. Position retaining fork, install Torx screw and tighten to specification. See TORQUE SPECIFICATIONS . Connect connectors to both shift control solenoid valves. Clean lock-up solenoid valve assembly with a lint-free cloth. Position lock-up valve assembly, assemble, install and tighten Torx screws to specification. See TORQUE SPECIFICATIONS . Install valve body assembly.

1. Remove valve body. See «VALVE BODY»(ref-169035-S12917945312004050600000). Release and remove clip securing pressure regulator solenoid valve harness to valve body. (Scheme 148) Disconnect connector from pressure regulator solenoid valve.
2. Disconnect connectors from lock-up solenoid valve and shift control solenoid valves MV1 and MV2. (Scheme 147)and (Scheme 151). Release harness from 5 clips on valve body and remove solenoid valve wire harness. (Scheme 152) Disconnect and remove speed sensor from harness. (Scheme 153)
3. To install, connect speed sensor to harness connector. Position harness to valve body. Connect connectors to shift control solenoid valves MV1 and MV2 and lock-up solenoid valve. Connect connector to pressure regulator solenoid valve and secure solenoid valve wire harness with clip to valve body. Position and secure harness in clips on valve body. Install valve body assembly.

Scheme 152

Scheme 153

1. Remove battery cover. Remove cooling fan cowl. If vehicle is equipped with engine oil cooler, go to next step. If vehicle is not equipped with engine oil cooler, go to step 9.
2. On 2003-2004 vehicles, go to step 4. On 1999-2002 vehicles, remove headlamp access covers from body. (Scheme 154) Remove screws securing turn indicator lamps to body and release lamps from 2 locating peg sockets in fenders. (Scheme 155) Disconnect connectors from turn indicator lamps and remove lamps.
3. Via access hole in wheel arch liners, remove screws securing headlamp finishers. (Scheme 156) Remove headlamp finishers from grille. Remove 2 screws securing lower corners of grille. (Scheme 157) Remove 3 scrivets, remove grille and go to step 5.
4. On 2003-2004 vehicles, remove 3 scrivets securing front grille to hood locking platform. (Scheme 158) Remove front grille and go to next step.
5. On all models, remove 6 scrivets and remove left and right air deflectors from front panel. (Scheme 159) Remove nut and move left horn aside. (Scheme 160)
6. Remove 2 bolts securing radiator left and right upper mounting brackets to body panel and remove brackets. Remove 4 screws securing air conditioning condenser left and right upper mounting brackets to condenser. (Scheme 161) Remove condenser upper mounting brackets with rubber mounts from radiator extension brackets.
7. Remove 2 bolts securing left and right extension brackets to radiator and remove brackets. (Scheme 162) Position absorbent cloth under each engine oil cooler hose connection to collect oil spillage. (Scheme 163) Push against coupling release rings and disconnect both hoses from engine oil cooler. Install plugs to open connections to prevent contamination.
8. Remove screw securing engine oil cooler to radiator. (Scheme 164) Release engine oil cooler from its location on radiator. Release radiator lower mountings from location in chassis and carefully move radiator towards engine sufficiently only to release engine oil cooler from radiator. Remove engine oil cooler.
9. Disconnect transmission fluid temperature sensor connector. (Scheme 165) Position absorbent cloth under each automatic transmission fluid cooler hose connection to collect spillage. Push against coupling release ring and disconnect both transmission fluid hoses from transmission fluid cooler. (Scheme 166)
10. Install plugs to open connections to prevent contamination. Remove screw and release transmission fluid cooler from radiator. Carefully move radiator towards engine and remove transmission fluid cooler. Remove transmission fluid temperature sensor and discard sealing washer.

Scheme 154

Scheme 155

Scheme 156

Scheme 157

Scheme 158

Scheme 159

Scheme 160

Scheme 161

Scheme 162

Scheme 163

Scheme 164

Scheme 165

Scheme 166

1. Use NEW sealing washer and tighten transmission fluid temperature sensor to specification. See «TORQUE SPECIFICATIONS»(ref-169035-S33236039582004112400000) . Install transmission fluid cooler, engage with radiator and secure with screw. Connect transmission fluid temperature sensor connector. Ensure connections are clean and install hoses to transmission fluid cooler. Check and if necessary top up transmission fluid. If vehicle is equipped with engine oil cooler, go to next step. If vehicle is not equipped with engine oil cooler, go to step 7 .
2. Install engine oil cooler to radiator, engage in location and secure with screw. Install radiator to location in chassis. Ensure connections are clean, then secure hoses to engine oil cooler. Install extension brackets to radiator and secure with bolts.
3. Install brackets with rubber mounts to extension brackets and secure to air conditioning condenser with screws. Install radiator upper mounting brackets and secure to body with bolts. Install left horn and secure with nut. Install left and right air deflectors to front panel and secure with scrivets.
4. On 1999-2002 vehicles, install headlamp access covers. Install grille and secure with scrivets and screws. Install headlamp finishers and secure with screws. Position turn indicator lamps and connect connectors. Install indicator lamps and tighten screws.
5. On 2003-2004 vehicles, install front grille and secure with scrivets.
6. On all models, top up engine oil.
7. Install and secure cooling fan cowl. Install battery cover.

1. Remove valve body. See «VALVE BODY»(ref-169035-S12917945312004050600000). Remove circlips and springs from automatic transmission casing noting location of long and short springs. Remove and discard seals using Seal Puller/Installer (LRT-44-005) from automatic transmission casing. (Scheme 167)
2. To install, clean automatic transmission casing, springs and circlips. Install new seals using Seal Puller/Installer (LRT-44-005), ensure seals are fully seated. (Scheme 168) Position springs in their correct locations and secure with circlips. (Scheme 169) Install valve body assembly.

Scheme 167

Scheme 168

Scheme 169

1. Remove battery cover. Disconnect battery ground lead. Remove 3 screws and trim clip securing lower trim casing to left front seat. (Scheme 170) Remove 3 nuts securing speaker power amplifier bracket to the body. (Scheme 171)
2. Disconnect connector from Electronic Automatic Transmission Electronic Control Unit (EAT ECU) located on underside of amplifier mounting bracket. Remove 2 nuts securing EAT ECU to mounting bracket and remove EAT ECU. (Scheme 172)

Scheme 170

Scheme 171

Scheme 172

Position Electronic Automatic Transmission Electronic Control Unit (EAT ECU) to mounting bracket and secure with nuts. Connect connector to EAT ECU. Position speaker power amplifier mounting bracket to body and secure with nuts. Position lower trim casing to seat and secure with screws and trim clip. Connect battery ground lead. Install battery cover.

1. Raise vehicle on ramp. See «JACKING & HOISTING»(ref-169035-S01110894692004112900000).
2. Drain automatic gearbox oil. See «DRAINING & REFILLING»(ref-169035-S23447299152004112400000).
3. Remove 6 bolts and spacers securing oil sump to gearbox, remove sump and discard gasket. (Scheme 173)
4. Clean oil sump and mating face.
5. Fit new gasket to oil sump, position sump to gearbox.
6. Position spacers and tighten bolts to 8 Nm (6 lbf. ft).
7. Fill automatic gearbox with oil.
8. Lower vehicle.

Scheme 173

1. Remove oil sump gasket. See «OIL SUMP GASKET»(ref-169035-S23247015932004112900000).
2. Remove Torx screw securing oil pick-up tube and remove tube. (Scheme 174)
3. Remove 2 Torx screws securing filter to valve body and discard "O" rings.
4. Clean filter and pick-up tube using a lint free cloth.
5. Fit new "O" rings to filter.
6. Position filter and tighten Torx screws to 8 Nm (6 lbf.ft).
7. Position oil pick-up tube and tighten Torx screw to 8 Nm (6 lbf.ft).
8. Fit oil sump gasket.

Scheme 174

1. Move the selector lever to position Park.
2. Remove nut securing selector lever to gearbox selector shaft and release lever.
3. Remove 2 bolts securing inhibitor switch to gearbox. (Scheme 175)
4. Release multiplug from gearbox bracket.
5. Release inhibitor switch from selector shaft.
6. Disconnect switch multiplug and remove switch.

Scheme 175

1. Ensure Park is selected by rotating selector shaft fully clockwise.
2. Engage Neutral by rotating selector shaft 2 detents anti-clockwise.
3. Position inhibitor switch to selector shaft, connect multiplug and secure multiplug to gearbox bracket.
4. Engage switch to selector shaft, and fit but do not tighten retaining bolts.
5. Fit tool LRT-44-011 to selector shaft. (Scheme 176)
6. Insert setting pin into tool. Rotate switch until setting pin engages with hole in switch as shown and tighten bolts to 10 Nm (7 lbf.ft).
7. Remove setting tool LRT-44-011.
8. Position selector lever to selector shaft and tighten nut to 26 Nm (19 lbf.ft).

Scheme 176