Automatic Transmission: Removal & Installation Land Rover Discovery III

Removal

1. Release fixings and remove battery cover.
2. Disconnect battery earth lead.
3. Raise vehicle on a ramp.
4. Remove 8 bolts securing center cross member and remove cross member. (Схема №2)
5. Remove exhaust front pipe.
6. Remove 3 nuts securing intermediate silencer to tail pipe.
7. Release and remove silencer from rubber mountings. (Схема №3)
8. Drain automatic gearbox oil. See «LUBRICATION»(ref-169035-S38733805962004112400000) in SERVICING - AUTOMATIC TRANSMISSION article.
9. Drain transfer gearbox oil. See «LUBRICATION»(ref-169354-S40370893592004120700000) TRANSFER CASE article.
10. Remove front propeller shaft. See «DRIVE SHAFT - FRONT»(ref-168563-S32339433462004111100000) in DRIVESHAFTS & UNIVERSAL JOINTS articles.
11. Remove rear propeller shaft. See «DRIVE SHAFT - REAR»(ref-168563-S07453910802004111100000) in DRIVESHAFTS & UNIVERSAL JOINTS articles.
12. Remove plug from torque converter housing to access torque converter bolts. (Схема №4)
13. Remove and discard 4 bolts securing torque converter to drive plate.
14. Remove hand brake drum retaining screw and remove brake drum. (Схема №5)
15. Remove 4 bolts from hand brake back plate, release back plate and tie aside.
16. Models fitted with high/low shift interlock solenoid: Release interlock solenoid multiplug and disconnect multiplug from main harness.
17. Models fitted with high/low shift interlock solenoid: Remove sleeve retaining rings and remove sleeve from high/low selector cable.
18. If fitted: Remove and discard clevis pin securing differential lock selector cable to transfer gearbox.
19. If fitted: Loosen locknuts securing differential lock selector cable to differential lock selector cable abutment bracket. (Схема №6)
20. If fitted: Release and remove differential lock selector cable from differential lock selector cable abutment bracket.
21. Remove clevis pin securing high/low ratio selector cable to selector lever, remove "C" clip and remove outer cable from abutment bracket. (Схема №7)
22. Up to 03 Model Year - If fitted: Disconnect 2 Lucars from differential lock switch and multiplugs from high/low ratio switch and neutral sensor. (Схема №8)
23. 03 Model Year onwards - If fitted: Release and disconnect both differential lock warning lamp switch multiplugs from main harness. (Схема №9)
24. Release transfer and automatic gearbox breather pipes from clip at rear of cylinder block.
25. Position gearbox support jack and secure tool LRT-99-008A to support plate on jack. (Схема №10)
26. Position a second support jack under engine using a block between engine sump and jack to prevent damage to sump.
27. Remove 4 bolts and nut, remove engine LH rear mounting. (Схема №11)
28. Remove 4 bolts and nut, remove engine RH rear mounting. (Схема №12)
29. Remove bolt securing gearbox oil cooler pipe clips to engine. (Схема №13)
30. Remove bolt and 2 nuts securing clamps to oil cooler pipes and remove clamps.
31. Loosen gearbox oil cooler pipe unions, release pipes from gearbox and discard "O" rings. (Схема №14)
32. Remove "C" clip securing selector cable to gearbox bracket. (Схема №15)
33. Remove nut securing selector lever to inhibitor switch and release lever.
34. Disconnect multiplug from inhibitor switch.
35. Loosen gearbox multiplug locking ring and disconnect plug.
36. Lower gearbox sufficiently to access bell housing bolts, take care not to trap any pipes or cables when lowering gearbox. (Схема №16)
37. Remove 14 bolts securing gearbox to engine.
38. With assistance remove gearbox from engine.
39. Fit suitable strap to retain torque converter. (Схема №17)

Installation

1. Clean gearbox to engine mating faces.
2. Remove torque converter retaining strap.
3. With assistance position gearbox to engine.
4. Fit gearbox bell housing bolts and tighten to 46 Nm (34 ft. lbs.).
5. Connect multiplug to gearbox and tighten locking ring.
6. Connect inhibitor switch multiplug.
7. If fitted: Connect and adjust differential lock selector cable. See «SHIFT CABLE»(ref-169035-S14728352852004112400000) in SERVICING - AUTOMATIC TRANSMISSION article.
8. Position selector lever to inhibitor switch and tighten nut to 25 Nm (18 ft. lbs.).
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 clip to engine sump.
14. Position engine RH and LH rear mountings and tighten bolts to 85 Nm (63 ft. lbs.) and nuts to 85 Nm (63 ft. lbs.).
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 gearbox 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, secure sleeve.
22. Models fitted with high/low shift interlock solenoid: Connect solenoid multiplug to main harness and secure multiplug to bracket.
23. Position hand brake back plate and tighten bolts to 75 Nm (55 ft. lbs.).
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 ft. lbs.).
27. Fit access plug to torque converter housing.
28. Fit rear propeller shaft.
29. Fit front propeller shaft.
30. Fill transfer gearbox with oil.
31. Fill automatic gearbox with oil.
32. Position intermediate silencer and secure to mounting rubbers.
33. Clean silencer and tail pipe mating faces.
34. Position new gasket to tail pipe and tighten nuts to 40 Nm (30 ft. lbs.).
35. Fit exhaust front pipe.
36. Position center cross member, fit bolts and tighten to 26 Nm (19 ft. lbs.).
37. Connect battery earth lead.
38. Fit battery cover and secure fixings.
39. Check and adjust selector cable.