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Discovery 2. Manual - part 573

AUTOMATIC GEARBOX - ZF4HP22 - 24

REPAIRS

44-31

11. Remove rear propeller shaft

PROPELLER SHAFTS, REPAIRS,

Propeller shaft - rear.

12. Remove plug from torque converter housing to

access torque converter bolts.

13. Remove and discard 4 bolts securing torque

converter to drive plate.

14. Remove hand brake drum retaining screw and

remove brake drum.

15. Remove 4 bolts from hand brake back plate,

release back plate and tie aside.

16. Remove retaining clip securing high/low ratio

selector cable to transfer gearbox lever,
remove 'C' clip and remove outer cable from
gearbox.

17. Disconnect 2 Lucars from differential lock

switch and multiplugs from high/low ratio switch
and neutral sensor.

18. Remove cable tie and multiplug from bracket

on transfer gearbox.

19. Release transfer and automatic gearbox

breather pipes from clip at rear of cylinder
block.

AUTOMATIC GEARBOX - ZF4HP22 - 24

44-32

REPAIRS

20. Position gearbox support jack and secure tool

LRT-99-008A to support plate on jack.

21. Position a second support jack under engine

using a block between engine sump and jack to
prevent damage to sump.

22. Remove 4 bolts and nut, remove engine LH

rear mounting.

23. Remove 4 bolts and nut, remove engine RH

rear mounting.

24. Remove bolt securing gearbox oil cooler pipe

clips to engine.

25. Remove bolt and 2 nuts securing clamps to oil

cooler pipes and remove clamps.

26. Loosen gearbox oil cooler pipe unions, release

pipes from gearbox and discard 'O' rings.

CAUTION: Always fit plugs to open
connections to prevent contamination.

AUTOMATIC GEARBOX - ZF4HP22 - 24

REPAIRS

44-33

27. Remove 'C' clip securing selector cable to

gearbox bracket.

28. Remove nut securing selector lever to inhibitor

switch and release lever.

29. Disconnect multiplug from inhibitor switch.
30. Loosen gearbox multiplug locking ring and

disconnect plug.

31. Lower gearbox sufficiently to access bell

housing bolts, take care not to trap any pipes or
cables when lowering gearbox.

32. Remove 14 bolts securing gearbox to engine.
33. With assistance remove gearbox from engine.

34. Fit suitable strap to retain torque converter.

Refit

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 lbf.ft)..

5. Connect multiplug to gearbox and tighten

locking ring.

6. Connect inhibitor switch multiplug.
7. Position selector lever to inhibitor switch and

tighten nut to 25 Nm (18 lbf.ft).

8. Position selector cable to gearbox and secure

with 'C' clip.

9. Clean oil pipe unions and fit new 'O' rings.

10. Position and tighten pipe unions to gearbox.
11. Position and tighten oil cooler pipe clamps.
12. Position and tighten oil cooler pipe clip to

engine sump.

13. Position engine RH and LH rear mountings

and tighten bolts to 85 Nm (63 lbf.ft) and nuts to
85 Nm (63 lbf.ft).

14. Secure gearbox breather pipes to bulkhead

clip.

15. Connect multiplugs to high/low ratio switch and

neutral sensor. Connect Lucar connectors to
differential lock switch.

16. Position cable tie and multiplug to transfer

gearbox bracket.

17. Connect high/low ratio cable to transfer box

and secure with retaining clips.

18. Position hand brake back plate and tighten