Removal & Installation - Automatic Transmission zf5hp24 Land Rover Range Rover L322

COMPONENT LOCATIONS

For transmission component locations (Scheme 73)and (Scheme 74).

Scheme 73

Scheme 74

1. Remove center console. See CENTER CONSOLE.
2. Disconnect shift interlock cable from ignition barrel. (Scheme 75)
3. Remove clip securing outer gear shift cable to mechanism.
4. Release and remove clip securing inner gear shift cable to mechanism, collect plastic spacer from cable.
5. Disconnect 2 multiplugs from selector mechanism.
6. Remove 3 nuts securing selector mechanism to carrier, remove mechanism.

Scheme 75

1. Position mechanism to carrier, fit nuts and tighten to 25 Nm (18 ft. lbs.).
2. Connect multiplugs to mechanism.
3. Fit plastic spacer to selector cable, secure cable to mechanism.
4. Connect shift interlock cable to ignition switch barrel.
5. Fit center console.

1. Release 4 clips securing gear-lever gaiter to center console.
2. Pull gear knob upwards to disengage locating tang from gear selector lever.

Scheme 76

1. Position gear knob to gear selector lever engaging locating tang on knob with slot in selector lever.
2. Push gear knob fully on to gear selector lever.
3. Fit and secure gear lever gaiter.

1. Position vehicle on lift.
2. Select "P".
3. Remove center console. See CENTER CONSOLE.
4. Remove clip securing outer gear shift cable to mechanism. (Scheme 77)
5. Release and remove clip securing inner gear shift cable to mechanism, collect plastic spacer from cable.
6. Loosen nut securing selector cable to selector lever and release selector cable from bracket. (Scheme 78)
7. Remove cable and grommet through carpet access panel.

Scheme 77

Scheme 78

1. Position cable through access panel, fit grommet and carpet.
2. Position selector cable through bracket and selector lever and secure selector cable to bracket.
3. Tighten nut securing selector cable to selector lever to 15 Nm (11 ft. lbs.).
4. Position cable to selector mechanism, fit spacer and secure with clips.
5. Fit center console.

1. Disconnect battery earth lead.
2. Remove air intake plenum.
3. Disconnect multiplug from inhibitor switch. (Scheme 79)
4. Remove bolt securing inhibitor switch multiplug bracket and release harness from gearbox.
5. Disconnect breather hose from gearbox.
6. Raise vehicle on lift.
7. Release inhibitor switch harness from retaining clips and position aside.
8. Remove nut securing selector lever to inhibitor switch and release lever. (Scheme 80)
9. Remove 2 bolts securing inhibitor switch guard and remove guard.
10. Remove 2 bolts securing inhibitor switch to gearbox and remove inhibitor switch. (Scheme 81)

Scheme 79

Scheme 80

Scheme 81

1. Clean inhibitor switch and mating face on gearbox.
2. Fit inhibitor switch onto dowel, fit bolts and tighten to 10 Nm (7 ft. lbs.)
3. Fit and secure inhibitor switch harness and connect multiplug.
4. Position inhibitor switch harness bracket, fit and tighten bolt to 10 Nm (7 ft. lbs.)
5. Fit inhibitor switch guard, fit and tighten bolts to 10 Nm (7 ft. lbs.)
6. Fit selector lever to inhibitor switch, fit nut and tighten to 10 Nm (7 ft. lbs.)
7. Lower vehicle.
8. Connect breather hose to gearbox.
9. Fit air intake plenum.
10. Connect battery earth lead.

1. Position vehicle on lift. See JACKING & HOISTING.
2. Disconnect battery earth lead.
3. Remove nut securing selector lever to selector shaft and release lever. (Scheme 82)
4. Remove 2 bolts securing inhibitor switch guard and remove guard. (Scheme 83)
5. Remove 2 bolts securing inhibitor switch to gearbox and remove inhibitor switch from selector shaft. (Scheme 84)
6. Position LRT-44-033/2 to seal recess and fit LRT-44-033/1 to LRT-44-033/2. Tighten LRT- 44-033/1 and remove selector shaft oil seal. (Scheme 85)

Scheme 82

Scheme 83

Scheme 84

Scheme 85

1. Clean selector shaft and seal recess.
2. Using LRT-44-033/3 fit new oil seal to selector shaft recess. (Scheme 86)
3. Clean inhibitor switch and mating face on gearbox.
4. Position inhibitor switch to dowel, fit 2 bolts securing inhibitor switch and tighten to 10 Nm (7 ft. lbs.).
5. Position inhibitor switch guard to gearbox, fit 2 bolts securing inhibitor switch guard and tighten to 10 Nm (7 ft. lbs.).
6. Position selector lever to selector shaft, fit nut securing selector shaft and tighten to 10 Nm (7 ft. lbs.).
7. Connect battery earth lead.

Scheme 86

1. Remove sump. See «FLUID PAN GASKET»(/land-rover/range-rover/l322-2002-2005/remont/automatic-trans/#removal-installation-automatic-transmission-zf5hp24).
2. Disconnect multiplugs from solenoid valves. (Scheme 87)
3. Remove 9 Torx bolts securing solenoid retaining bracket, remove bracket.
4. Remove solenoid valve and remove "O" rings where fitted.

Scheme 87

1. Clean solenoid mating faces.
2. Fit new "O" rings to solenoid and lubricate with transmission fluid.
3. Fit solenoid to valve block.
4. Fit solenoid retaining bracket, fit Torx bolts and tighten to 10 Nm (7 ft. lbs.)
5. Connect multiplugs to solenoid valves.
6. Fit sump.

1. Disconnect battery earth lead.
2. Remove 10 Allen screws securing "E" box cover and remove cover. (Scheme 88)
3. Disconnect 3 blue multiplugs from Electronic Automatic Transmission - Electronic Control Unit (EAT ECU). (Scheme 89)
4. Release EAT ECU from mounting bracket and remove from "E" box.

Scheme 88

Scheme 89

1. Fit EAT ECU in mounting bracket and connect multiplugs.
2. Fit "E" box cover and tighten Allen screws to 2 Nm (1.5 ft. lbs.).
3. Connect battery earth lead.

1. Remove gearbox fluid filter. See «FLUID FILTER»(/land-rover/range-rover/l322-2002-2005/remont/automatic-trans/#removal-installation-automatic-transmission-zf5hp24).
2. Disconnect multiplug from gearbox. (Scheme 90)
3. Remove retaining clip from multiplug and release plug from gearbox casing.
4. Remove 2 Torx bolts securing speed sensor clamps, remove clamps and sensors. (Scheme 91)
5. Evenly and progressively loosen and remove 22 large shouldered Torx bolts from valve block. (Scheme 92)
6. Remove valve block assembly.
7. Noting fitted position, disconnect 10 multiplugs from sensors and solenoids. (Scheme 93)
8. Remove harness, remove and discard "O" rings.

Scheme 90

Scheme 91

Scheme 92

Scheme 93

1. Clean multiplug and gearbox recess.
2. Fit new "O" rings to harness and lubricate with transmission fluid.
3. Position harness to valve block and secure with clips.
4. Connect multiplugs to sensors and solenoids.
5. Clean valve block and mating faces.
6. With assistance fit valve block and multiplug, ensure selector fork locates on peg.
7. Evenly and progressively fit and tighten 22 valve block Torx bolts to 10 Nm (7 ft. lbs.)
8. Fit gearbox multiplug retaining clip.
9. Connect multiplug to gearbox connector.
10. Fit speed sensor to valve block, position clamp and tighten Torx bolt to 10 Nm (7 ft. lbs.).
11. Fit gearbox fluid filter.

PICK UP - SPEED SENSOR - COUNTERSHAFT

Note. This procedure also covers, pick up - speed sensor - mainshaft

1. Remove sump. See «FLUID PAN GASKET»(/land-rover/range-rover/l322-2002-2005/remont/automatic-trans/#removal-installation-automatic-transmission-zf5hp24).
2. Remove Torx bolt securing speed sensor clamp and release sensor from valve block. (Scheme 94)
3. Disconnect multiplug from speed sensor.

Scheme 94

1. Clean countershaft speed sensor and sensor location.
2. Connect multiplug to countershaft speed sensor
3. Fit speed sensor to valve block, position clamp and tighten Torx bolt to 10 Nm (7 ft. lbs.).
4. Fit sump. See «FLUID PAN GASKET»(/land-rover/range-rover/l322-2002-2005/remont/automatic-trans/#removal-installation-automatic-transmission-zf5hp24) .

1. Remove transmission assembly. See «GEARBOX/CONVERTER & TRANSFER GEARBOX ASSEMBLY - REMOVE FOR ACCESS AND REFIT»(/land-rover/range-rover/l322-2002-2005/remont/automatic-trans/#removal-installation-automatic-transmission-zf5hp24).
2. Remove torque converter retaining plate.
3. Fit tool LRT-44-010 to torque converter and remove torque converter from gearbox. (Scheme 95)
4. Remove retaining ring securing torque converter oil seal. (Scheme 96)
5. Carefully remove oil seal.

Scheme 95

Scheme 96

Scheme 97

1. Clean torque converter oil seal recess in gearbox. Lubricate torque converter oil seal with clean transmission fluid.
2. Using LRT-44-031 fit new oil seal. (Scheme 97)
3. Fit retaining ring securing oil seal.
4. Fit torque converter to gearbox, ensure converter is fully located onto oil pump drive.
5. Remove tool LRT-44-010 from torque converter.
6. Fit converter retaining plate and secure with bolts.
7. Fit transmission assembly.

1. Remove transmission assembly. See «GEARBOX/CONVERTER & TRANSFER GEARBOX ASSEMBLY - REMOVE FOR ACCESS AND REFIT»(/land-rover/range-rover/l322-2002-2005/remont/automatic-trans/#removal-installation-automatic-transmission-zf5hp24).
2. Remove gearbox assembly from transmission jack and lower onto bench.
3. Release transfer gearbox breather pipe from clips. (Scheme 98)
4. Disconnect breather hose from gearbox.
5. Remove 9 Torx bolts and remove transfer gearbox. (Scheme 99)
6. Remove bolt securing inhibitor switch multiplug bracket and release harness from gearbox. (Scheme 100)
7. Remove 2 bolts securing inhibitor switch guard and remove guard. (Scheme 101)
8. Remove 2 bolts securing inhibitor switch to gearbox and remove inhibitor switch.

Scheme 98

Scheme 99

Scheme 100

Scheme 101

1. Clean inhibitor switch and mating face on gearbox.
2. Fit inhibitor switch onto dowel, fit bolts and tighten to 10 Nm (7 ft. lbs.)
3. Fit inhibitor switch guard, fit and tighten bolts to 10 Nm (7 ft. lbs.)
4. Fit inhibitor switch harness to gearbox and tighten multiplug bracket bolt to 10 Nm (7 ft. lbs.).
5. Clean transfer gearbox and mating face dowels and dowel holes.
6. Align transfer gearbox to automatic gearbox, fit Torx bolts and tighten to 43 Nm (32 ft. lbs.).
7. Connect breather hose to gearbox.
8. Secure transfer gearbox breather pipe to automatic gearbox casing.
9. Remove gearbox assembly from bench and secure on transmission jack.
10. Fit transmission assembly.

1. Position vehicle on lift. See JACKING & HOISTING.
2. Disconnect battery earth lead.
3. Use LRT-12-214 and LRT-12-215 to loosen viscous coupling lock nut and remove fan assembly from coolant pump. (Scheme 102)
4. Remove air intake plenum by unfastening clips.
5. Disconnect multiplug from inhibitor switch harness. (Scheme 103)
6. Release clips securing left hand oxygen sensor lead from gearbox bell housing.
7. Remove 2 Torx bolts from top of bell housing. (Scheme 104)
8. Raise vehicle on lift.
9. Remove rear propeller shaft. See «REAR DRIVE SHAFT»(/land-rover/range-rover/l322-2002-2005/remont/driveshaft-universal-joints/#driveshafts-universal-joints).
10. Remove front propeller shaft. See «FRONT DRIVE SHAFT»(/land-rover/range-rover/l322-2002-2005/remont/driveshaft-universal-joints/#driveshafts-universal-joints).
11. Remove 5 nuts, release left hand heat shield and remove. (Scheme 105)
12. Drain gearbox fluid. See «DRAINING & REFILLING»(/land-rover/range-rover/l322-2002-2005/remont/automatic-trans/#servicing-automatic-transmission__draining-refilling).
13. Using LRT-44-032 support gearbox on jack, arrow in graphic points towards front of vehicle. (Scheme 106)
14. Remove nut and bolt securing mounting to cross member. (Scheme 107)
15. Remove 6 bolts securing cross member and remove cross member.
16. Remove snubbers from mounting. (Scheme 108)
17. Lower gearbox on jack.
18. Disconnect multiplug from high/low shift motor. (Scheme 109)
19. Disconnect multiplug from gearbox housing. (Scheme 90)
20. Release clips securing oxygen sensor leads to transfer gearbox.
21. Remove nut securing selector lever to gearbox selector shaft and release lever. (Scheme 110)
22. Remove 2 bolts securing selector cable support bracket to gearbox and tie cable aside. (Scheme 111)
23. Remove bolt securing crankshaft sensor, remove sensor and position aside. (Scheme 112)
24. Release right hand oxygen sensor harness from gearbox casing.
25. Remove undertray. See UNDERTRAY.
26. Remove grommet from bell housing to gain access to torque converter retaining bolts. (Scheme 113)
27. Rotate crankshaft for access and remove 4 bolts securing drive plate to torque converter.
28. Remove 2 bolts securing starter motor and tie aside. (Scheme 114)
29. Remove bolt securing fluid cooler saddle clamp to sump. (Scheme 115)
30. Remove banjo bolt securing fluid cooler pipe to left hand side of gearbox and discard sealing washers. (Scheme 116)
31. Release fluid cooler pipe from right hand side of gearbox and discard "O" ring.
32. Remove 8 Torx bolts from bell housing. (Scheme 117)
33. With assistance, carefully remove gearbox from engine. Ensure torque converter remains with gearbox.
34. Fit converter retaining plate and secure with bolts. (Scheme 118)

Scheme 102

Scheme 103

Scheme 104

Scheme 105

Scheme 106

Scheme 107

Scheme 108

Scheme 109

Scheme 110

Scheme 111

Scheme 112

Scheme 113

Scheme 114

Scheme 115

Scheme 116

Scheme 117

Scheme 118

1. Clean mounting and mating faces.
2. Remove torque converter retaining plate.
3. With assistance, carefully fit gearbox to engine. Ensure engagement of torque converter spigot and gearbox housing onto dowels.
4. Fit 8 Torx bolts securing automatic gearbox to engine, tighten to 45 Nm (33 ft. lbs.)
5. Clean fluid cooler pipes unions and mating faces.
6. Position fluid cooler pipe to left hand side of gearbox.
7. Lubricate fluid cooler sealing washers with transmission fluid, fit banjo bolt to gearbox and tighten to 37 Nm (27 ft. lbs.)
8. Fit and lubricate new "O" ring to fluid cooler pipe, fit pipe to gearbox and tighten to 37 Nm (27 ft. lbs.).
9. Position fluid cooler saddle clamp, fit bolt and tighten to 6 Nm (4.4 ft. lbs.)
10. Fit starter motor and tighten bolts to 45 Nm (33 ft. lbs.).
11. Fit bolts securing drive plate to torque converter and tighten to 45 Nm (33 ft. lbs.)
12. Fit grommet to gearbox bell housing.
13. Fit undertray.
14. Fit oxygen sensor leads to gearbox casing.
15. Clean crankshaft sensor and mating face.
16. Position crankshaft sensor, fit bolt and tighten to 6 Nm (4.4 ft. lbs.)
17. Position selector cable support bracket to gearbox, fit bolts and tighten to 10 Nm (7 ft. lbs.)
18. Fit selector lever to inhibitor switch, fit nut and tighten to 10 Nm (7 ft. lbs.)
19. Fit and secure oxygen sensor leads to transfer gearbox.
20. Connect multiplug to gearbox connector.
21. Connect multiplug to high/low shift motor.
22. Raise gearbox on jack.
23. Fit snubbers.
24. Fit cross member to mounting, fit nut and bolt but do not tighten at this stage.
25. Align cross member, fit bolts and tighten to 68 Nm (50 ft. lbs.).
26. Remove support from gearbox.
27. Tighten nut and bolt securing mounting to cross member to 100 Nm (74 ft. lbs.).
28. Fit heat shield and secure with nuts.
29. Fit rear propeller shaft.
30. Fit front propeller shaft.
31. Lower vehicle.
32. Fit top bell housing Torx bolts and tighten to 25 Nm (18 ft. lbs.)
33. Fit and secure left hand oxygen sensor lead to gearbox bell housing.
34. Connect inhibitor switch multiplug.
35. Fit air intake plenum.
36. Fit fan to pulley and tighten viscous coupling nut to 40 Nm (30 ft. lbs.).
37. Connect battery earth lead.
38. Fill gearbox with fluid.

1. Remove transfer case. See «GEARBOX/CONVERTER & TRANSFER GEARBOX ASSEMBLY - REMOVE FOR ACCESS AND REFIT»(/land-rover/range-rover/l322-2002-2005/remont/automatic-trans/#removal-installation-automatic-transmission-zf5hp24).
2. Remove 4 Torx bolts securing output flange housing and remove housing. (Scheme 119)
3. Remove bearing.
4. Carefully remove and discard oil seal and "O" ring.

Scheme 119

1. Clean housing and mating faces.
2. Using LRT-44-029 fit new oil seal. (Scheme 120)
3. Lubricate new "O" ring and fit to housing.
4. Lubricate and fit bearing.
5. Fit housing to gearbox, fit and tighten Torx bolts to 10 Nm (7 ft. lbs.)
6. Fit transfer gearbox.

Scheme 120

1. Drain gearbox fluid. See «DRAINING & REFILLING»(/land-rover/range-rover/l322-2002-2005/remont/automatic-trans/#servicing-automatic-transmission__draining-refilling).
2. Remove nut securing selector lever to gearbox selector shaft and release lever. (Scheme 121)
3. Remove 2 bolts securing inhibitor switch guard and remove guard.
4. Evenly and progressively loosen and remove 22 Torx bolts from sump. (Scheme 122)
5. Remove sump and discard gasket.

Scheme 121

Scheme 122

1. Clean gearbox sump mating surfaces.
2. Fit new gasket to sump, position sump to gearbox.
3. Evenly and progressively tighten sump Torx bolts to 10 Nm (7 ft. lbs.).
4. Fit inhibitor switch guard, fit and tighten bolts to 10 Nm (7 ft. lbs.)
5. Fit selector lever to inhibitor switch, fit nut and tighten to 10 Nm (7 ft. lbs.).
6. Refill gearbox with transmission fluid.

1. Remove sump and discard gasket. See «FLUID PAN GASKET»(/land-rover/range-rover/l322-2002-2005/remont/automatic-trans/#removal-installation-automatic-transmission-zf5hp24).
2. Remove 2 Torx bolts and remove filter from valve block, discard "O" ring. (Scheme 123)

Scheme 123

1. Clean filter mating surfaces.
2. Ensure new filter has "O" ring fitted, then fit filter to valve block.
3. Fit Torx bolts to gearbox filter and tighten to 6 Nm (4.4 ft. lbs.).
4. Fit sump.

1. Position vehicle on lift. See JACKING & HOISTING.
2. Disconnect battery earth lead.
3. Drain cooling system. See «DRAINING & REFILLING COOLING SYSTEM»(/land-rover/range-rover/l322-2002-2005/remont/accessory-drive-belts/#specifications-drive-belt-routing__draining-refilling-cooling-system).
4. Place container below gearbox fluid cooler.
5. Release quick release connectors and disconnect gearbox fluid cooler pipes from gearbox fluid cooler.
6. Release clip securing gearbox fluid cooler and remove gearbox fluid cooler from manifold. (Scheme 125)
7. Discard "O" rings.

Scheme 124

Scheme 125

1. Clean gearbox fluid cooler mating faces.
2. Lubricate new "O" rings with clean transmission fluid and fit "O" rings to fluid cooler.
3. Fit gearbox fluid cooler to gearbox fluid cooler manifold and secure with clip.
4. Connect gearbox fluid cooler pipes to gearbox fluid cooler.
5. Remove container from below gearbox fluid cooler.
6. Connect battery earth lead.
7. Fill cooling system.
8. Check and top up gearbox fluid.
9. Check gearbox fluid cooler and connections for leaks.

1. Drain cooling system. See «DRAINING & REFILLING COOLING SYSTEM»(/land-rover/range-rover/l322-2002-2005/remont/accessory-drive-belts/#specifications-drive-belt-routing__draining-refilling-cooling-system).
2. Release clips and disconnect 3 coolant hoses from the transmission fluid cooler. (Scheme 126)
3. Remove Torx screw securing gearbox fluid cooler to cooling pack and remove the gearbox fluid cooler.
4. Remove and discard gearbox fluid cooler "O"rings.

Scheme 126

1. Clean hose connections.
2. Fit new gearbox fluid cooler "O" rings.
3. Fit gearbox fluid cooler to cooling pack and secure with screw.
4. Connect coolant hoses to gearbox fluid cooler and secure with clips.
5. Fill cooling system.

1. Remove gearbox fluid filter. See «FLUID FILTER»(/land-rover/range-rover/l322-2002-2005/remont/automatic-trans/#removal-installation-automatic-transmission-zf5hp24).
2. Disconnect multiplug from gearbox. (Scheme 127)
3. Remove retaining clip from multiplug and release plug from gearbox casing.
4. Remove 2 Torx bolts securing speed sensor clamps, remove clamps and sensors. (Scheme 128)
5. Evenly and progressively loosen and remove 22 large shouldered Torx bolts from valve block. (Scheme 129)
6. Remove valve block assembly.

Scheme 127

Scheme 128

Scheme 129

1. Clean valve block and mating faces.
2. With assistance fit valve block and multiplug, ensure selector fork locates on peg.
3. Evenly and progressively fit and tighten 22 valve block Torx bolts to 10 Nm (7 ft. lbs.)
4. Fit gearbox multiplug retaining clip.
5. Connect multiplug to gearbox connector.
6. Fit speed sensor to valve block, position clamp and tighten Torx bolt to 10 Nm (7 ft. lbs.).
7. Fit gearbox fluid filter.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• REAR DRIVE SHAFT
• DRAINING & REFILLING
• DRAINING & REFILLING COOLING SYSTEM
• FLUID PAN GASKET