Land Rover Range Rover 2002my On Workshop Procedures Lm 6th Edition Nas Rover Manual

							AUTOMATIC TRANSMISSION - ZF 5HP24
44-2-16 REPAIRS
25.Remove undertray.
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Undertray - front.
26.Remove grommet from bell housing to gain 
access to torque converter retaining bolts.
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.29.Remove bolt securing fluid cooler saddle clamp 
to sump.
30.Remove banjo bolt securing fluid cooler pipe to 
LH side of gearbox and discard sealing 
washers.
31.Release fluid cooler pipe from RH side of 
gearbox and discard O ring.
32.Remove 8 Torx bolts from bell housing.
M44 1872
M44 1867 
						

							AUTOMATIC TRANSMISSION - ZF 5HP24
REPAIRS 44-2-17
33.With assistance, carefully remove gearbox 
from engine. Ensure torque converter remains 
with gearbox.
34.Fit converter retaining plate and secure with 
bolts.
Refit
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 lbf.ft)
5.Clean fluid cooler pipes unions and mating 
faces.
6.Position fluid cooler pipe to LH side of gearbox.
7.Lubricate fluid cooler sealing washers with 
transmission fluid, fit banjo bolt to gearbox and 
tighten to 37 Nm (27 lbf.ft)
8.Fit and lubricate new O ring to fluid cooler pipe, 
fit pipe to gearbox and tighten to 37 Nm (27 
lbf.ft).
9.Position fluid cooler saddle clamp, fit bolt and 
tighten to 6 Nm (4.4 lbf.ft)
10.Fit starter motor and tighten bolts to 45 Nm (33 
lbf.ft).
11.Fit bolts securing drive plate to torque converter 
and tighten to 45 Nm (33 lbf.ft)
12.Fit grommet to gearbox bell housing.
13.Fit undertray.
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Undertray - front.
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 lbf.ft) 
17.Position selector cable support bracket to 
gearbox, fit bolts and tighten to 10 Nm (7 lbf.ft) 
18.Fit selector lever to inhibitor switch, fit nut and 
tighten to 10 Nm (7 lbf.ft)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 lbf.ft).
26.Remove support from gearbox.
27.Tighten nut and bolt securing mounting to cross 
member to 100 Nm (74 lbf.ft).
28.Fit heat shield and secure with nuts.
29.Fit rear propeller shaft.
 
 +  DRIVESHAFTS, REPAIRS, Propeller 
shaft - rear.
30.Fit front propeller shaft.
 
 +  DRIVESHAFTS, REPAIRS, Propeller 
shaft - front.
31.Lower vehicle.
32.Fit top bell housing Torx bolts and tighten to 25 
Nm (18 lbf.ft) 
33.Fit and secure LH oxygen sensor lead to 
gearbox bell housing.
34.Connect inhibitor switch multiplug.
35.Fit air intake plenum.
 
 +  HEATING AND VENTILATION, 
REPAIRS, Plenum - air intake.
36.Fit fan to pulley and tighten viscous coupling 
nut to 40 Nm (30 lbf.ft).
37.Connect battery earth lead.
38.Fill gearbox with fluid.
 
 +  AUTOMATIC TRANSMISSION - ZF 
5HP24, ADJUSTMENTS, Gearbox fluid - 
drain & refill.
M44 1870 
						

							AUTOMATIC TRANSMISSION - ZF 5HP24
44-2-18 REPAIRS
Fluid seal - rear
$% 44.20.18
Remove
1.Remove transfer gearbox.
 
 +  TRANSFER BOX, REPAIRS, 
Transfer gearbox - V8.
2.Remove 4 Torx bolts securing output flange 
housing and remove housing.
3.Remove bearing.
4.Carefully remove and discard oil seal and O 
ring.
Refit
1.Clean housing and mating faces.
2.Using LRT-44-029 fit new oil seal.
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 lbf.ft)
6.Fit transfer gearbox.
 
 +  TRANSFER BOX, REPAIRS, 
Transfer gearbox - V8.
Gasket - fluid pan
$% 44.24.05
Remove
1.Drain gearbox fluid.
 
 +  AUTOMATIC TRANSMISSION - ZF 
5HP24, ADJUSTMENTS, Gearbox fluid - 
drain & refill.
2.Remove nut securing selector lever to gearbox 
selector shaft and release lever.
3.Remove 2 bolts securing inhibitor switch guard 
and remove guard.
4.Evenly and progressively loosen and remove 
22 Torx bolts from sump.
5.Remove sump and discard gasket.
M44 1859
LRT-44-029 
						

							AUTOMATIC TRANSMISSION - ZF 5HP24
REPAIRS 44-2-19
Refit
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 lbf.ft).
4.Fit inhibitor switch guard, fit and tighten bolts to 
10 Nm (7 lbf.ft)
5.Fit selector lever to inhibitor switch, fit nut and 
tighten to 10 Nm (7 lbf.ft)
6.Refill gearbox with transmission fluid.
 
 +  AUTOMATIC TRANSMISSION - ZF 
5HP24, ADJUSTMENTS, Gearbox fluid - 
drain & refill.
Filter - fluid 
$% 44.24.07
Remove
1.Remove sump and discard gasket.
 
 +  AUTOMATIC TRANSMISSION - ZF 
5HP24, REPAIRS, Gasket - fluid pan.
2.Remove 2 Torx bolts and remove filter from 
valve block, discard O ring.
Refit
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 lbf.ft). 
4.Fit sump.
 
 +  AUTOMATIC TRANSMISSION - ZF 
5HP24, REPAIRS, Gasket - fluid pan.
M44 1811 
						

							AUTOMATIC TRANSMISSION - ZF 5HP24
44-2-20 REPAIRS
Fluid cooler
$% 44.24.10 
Before disconnecting the battery, ensure all text and 
cautions in the battery disconnection section are 
observed. 
 
 +  GENERAL INFORMATION, Electrical 
Precautions.
Remove
1.Position vehicle on lift.
2.Disconnect battery earth lead.
3.Drain cooling system
 
 +  COOLING SYSTEM - V8, 
ADJUSTMENTS, Coolant - drain, flush & 
refill.
4.Place container below gearbox fluid cooler.
5.Release quick release connectors and 
disconnect gearbox fluid cooler pipes from 
gearbox fluid cooler.
CAUTION: Always fit plugs to open 
connections to prevent contamination.6.Release clip securing gearbox fluid cooler and 
remove gearbox fluid cooler from manifold.
7.Discard O rings.
Refit
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.
 
 +  COOLING SYSTEM - V8, 
ADJUSTMENTS, Coolant - drain, flush & 
refill.
8.Check and top up gearbox fluid. 
 
 +  MAINTENANCE, PROCEDURES, 
Gearbox fluid - V8.
9.Check gearbox fluid cooler and connections for 
leaks. 
						

							AUTOMATIC TRANSMISSION - ZF 5HP24
REPAIRS 44-2-21
Thermostat - fluid cooler 
$% 44.24.17
Remove
1.Drain cooling system
 
 +  COOLING SYSTEM - V8, 
ADJUSTMENTS, Coolant - drain, flush & 
refill.
2.Release clips and disconnect 3 coolant hoses 
from the transmission fluid cooler.
CAUTION: Always fit plugs to open 
connections to prevent contamination.
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.
Refit
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.
 
 +  COOLING SYSTEM - V8, 
ADJUSTMENTS, Coolant - drain, flush & 
refill.
Valve body assembly 
$% 44.40.01
Remove
1.Remove gearbox fluid filter.
 
 +  AUTOMATIC TRANSMISSION - ZF 
5HP24, REPAIRS, Filter - fluid.
2.Disconnect multiplug from gearbox.
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.
M44 1937
M44 1813 
						

							AUTOMATIC TRANSMISSION - ZF 5HP24
44-2-22 REPAIRS
5.Evenly and progressively loosen and remove 
22  large shouldered Torx bolts from valve 
block.
6.Remove valve block assembly.
Refit
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 lbf.ft)
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 lbf.ft).
7.Fit gearbox fluid filter.
 
 +  AUTOMATIC TRANSMISSION - ZF 
5HP24, REPAIRS, Filter - fluid. 
						

							DRIVESHAFTS
REPAIRS 47-1
DRIV ESHAFTS REPAIRS
Drive shaft - front - LH 
$% 47.10.01
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a 
vehicle supported only by a jack. Always 
support the vehicle on safety stands.
2.Remove road wheel.
3.Release drive shaft hub nut stake.
4.With an assistant applying brakes, remove and 
discard drive shaft hub nut.
5.Remove brake disc.
 
 +  BRAKES, REPAIRS, Brake disc - 
front.
6.Release ABS sensor lead from clip.
7.Release sensor lead from damper, remove 
Allen screw and release ABS sensor from hub.8.Remove and discard nut securing track rod ball 
joint to steering arm.
9.Fit an M14 nut to ball pin, flush with end of pin.
10.Using LRT-57-036 separate ball pin from 
steering arm. Remove M14 nut and release ball 
pin from steering arm.
CAUTION: Ensure ball joint seal is not 
damaged. A damaged seal will lead to 
premature failure of the joint.
11.Remove nut securing height sensor link to 
lower arm and release link.
CAUTION: Use an open ended spanner on 
flats provided to prevent ball joint rotating.
12.Loosen bolt securing lower arm to subframe 
one quarter of a turn.
13.Remove nut securing lower arm ball joint to 
hub.
M47 0412
M54 0179
LRT-57-036 
						

							DRIVESHAFTS
47-2 REPAIRS
14.Using LRT-54-027 release lower arm ball joint 
and disconnect lower arm from hub.
CAUTION: Ensure ball joint seal is not 
damaged. A damaged seal will lead to 
premature failure of the joint.
15.Loosen bolt securing tie rod to subframe one 
quarter of a turn.
16.Remove nut securing tie rod to ball joint.17.Using LRT-54-027 release tie rod from ball joint
CAUTION: Ensure ball joint seal is not 
damaged. A damaged seal will lead to 
premature failure of the joint.
18.Fit centre screw LRT-60-030/3 to LRT-60-030/
1 and fit to hub with spacer LRT-60-030/2. 
Secure with nuts LRT-60-030/5.
19.Tighten centre screw to press drive shaft from 
flange.
20.Remove tools.
21.Position container to collect oil spillage.
M60 0789LRT -54-027M60 0787
LRT -54-027 
						

							DRIVESHAFTS
REPAIRS 47-3
22.Fit LRT-54-026 to drive shaft inboard joint.
23.Using  levers, release drive shaft from 
differential.
24.Release drive shaft from hub.
25.Remove drive shaft assembly, keep drive shaft 
horizontal to avoid damaging differential oil 
seal.
26.Remove and discard drive shaft circlip.
Refit
1.Clean end of drive shaft and location in 
differential.
2.Fit new circlip to drive shaft.
3.Lubricate oil seal lip with clean differential oil. 
 
 +  CAPACITIES, FLUIDS, 
LUBRICANTS AND SEALANTS, 
Lubrication.
4.Fit drive shaft ensuring circlip is fully engaged.
CAUTION: Pull the drive shaft to ensure the 
circlip is fully engaged and retains the shaft.
5.Clean drive shaft and flange splines.
6.Lightly lubricate splines and oil seal running 
surface.
 
 +  CAPACITIES, FLUIDS, 
LUBRICANTS AND SEALANTS, 
Lubrication.
7.Locate drive shaft in hub.8.Fit LRT-60-030/4 to drive shaft.
9.Fit LRT-60-030/1 with spacer LRT-60-030/2 
and secure with nuts LRT-60-030/5.
10.Fit nut to LRT-60-030/4 and tighten nut to pull 
drive shaft into drive flange.
11.Remove tools.
12.Clean ball joint tapers and taper seats.
13.Connect tie rod to ball joint, fit nut and tighten to 
80 Nm (59 lbf.ft).
14.Connect lower arm ball joint to hub, fit nut and 
tighten to 80 Nm (59 lbf.ft).
15.Connect height sensor link to lower arm, fit nut 
and tighten to 8 Nm (6 lbf.ft).  
CAUTION: Ensure height sensor arm is 
pointing outwards.
16.Connect ball joint to steering arm, fit new nut 
and tighten to 80 Nm (59 lbf.ft).
17.Clean ABS sensor, smear sensor with an anti-
seize grease and fit sensor to hub.
 
 +  CAPACITIES, FLUIDS, 
LUBRICANTS AND SEALANTS, 
Lubrication.
18.Fit Allen screw securing ABS sensor and 
tighten to 8 Nm (6 lbf.ft).
19.Secure sensor lead to damper.
20.Fit front brake disc.
 
 +  BRAKES, REPAIRS, Brake disc - 
front.
21.Fit new hub nut and tighten to 420 Nm (311 
lbf.ft).
22.Stake nut to shaft.
23.Fit road wheel and tighten nuts to 140 Nm (103 
lbf.ft).
24.Remove stands and lower vehicle.
25.Tighten new bolt securing lower arm to 
subframe to 165 Nm (121 lbf.ft), plus a further 
90°.
M47 0414
LRT-54-026