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AUTOMATIC GEARBOX - ZF4HP22 - 24 REPAIRS 44-31 40. Fit suitable strap to retain torque converter. Refit 1. Clean gearbox to engine mating faces. 4. Fit but do not tighten six bolts securing gearbox housing to engine. 5. Connect multiplug to gearbox and tighten locking ring. 6. Connect multiplug to inhibitor switch. selector cable. ADJUSTMENTS, Cable - selector - 8. Position selector lever to inhibitor switch and tighten nut to 25 Nm (18 lbf.ft). 9. Position selector cable to gearbox and secure with 'C' clip. 10. Clean oil pipe unions and fit new 'O' rings. engine sump and alternator bracket. 14. Position engine RH and LH rear mountings and tighten bolts to 85 Nm (63 lbf.ft) and nuts to 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 17. 03 Model Year onwards - If fitted: Connect differential lock warning lamp switch multiplugs 18. Position cable tie and multiplug to transfer box 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 22. Models fitted with high/low shift interlock solenoid: Connect solenoid multiplug to main 23. Position handbrake backplate and tighten bolts to 75 Nm (55 lbf.ft). 24. Fit hand brake drum and tighten screw. gearbox. 26. Rotate engine to align torque converter, fit new bolts and tighten to 50 Nm (37 lbf.ft). 27. Fit rear propeller shaft. 28. Fit front propeller shaft. 29. Fill transfer gearbox with oil. 30. Fill automatic gearbox with oil. 31. Position intermediate silencer and secure to mounting rubbers. 32. Clean silencer and tail pipe mating faces. nuts to 25 Nm (18 lbf.ft). 34. Fit exhaust front pipe. SYSTEMS - Td5, REPAIRS, Pipe - front. 35. Fit bolt securing closing plate to gearbox housing and tighten to 7 Nm (5.2 lbf.ft). 36. Fit upper bolts securing gearbox housing to engine and tighten to 50 Nm (37 lbf.ft). 37. Fit starter motor. REPAIRS, Starter motor - diesel. 38. Tighten remaining gearbox housing to engine bolts to 50 Nm (37 lbf.ft). 39. Connect battery earth lead. |