Range Rover. Manual - part 163
ZF AUTO
21
REPAIR
Refit
39. Clean mating faces of engine and gearbox,
dowel and dowel holes.
40. Ensure drive plate and convertor mating faces
are clean.
41. Remove 2 nuts and bolts and remove convertor
retaining strap.
42. With assistance, fit transmission assembly to
engine.
CAUTION: Ensure that gearbox is located
on both dowels, or transmission damage
may occur.
43. Fit crash bracket to gearbox flange and fit and
tighten engine to gearbox bolts to
45 Nm
(33 lbf.ft).
44. Align drive plate to convertor and tighten bolts to
50 Nm (37 lbf.ft).
45. Fit access plug.
46. Fit new gasket and lower access cover. Secure
cover with bolts.
47. Clean gearbox fluid cooler pipe unions, fit new
’O’ rings and tighten union nuts to
22 Nm
(16 lbf.ft).
48. Clean breather pipe bolts and banjos, fit new
sealing washers and tighten bolts to
15 Nm
(11 lbf.ft).
49. Fit gearbox fluid cooler pipe clamp and secure
with bolt.
50. Align fuel and purge pipe brackets to gearbox
and transfer box and secure with 2 bolts and
1 clip.
51. Connect multiplugs to output shaft speed sensor
and High/Low motor.
52. Connect Lucars to transfer box temperature
sensor.
53. Connect multiplugs to gearbox selection position
switch and gearbox speed sensor.
54. Secure harness to clips.
55. Align harness support bracket and gear selector
cable abutment bracket to gearbox and secure
with bolts.
56. Connect gear selector cable trunnion to lever
and fit split pin.
57. Adjust gear selector cable.
See this section.
58. Raise gearbox on transmission jack.
59. Fit and engage handbrake cable grommet in
transmission tunnel.
60. Clean propeller shaft and transfer box flanges.
61. Fit shafts to transfer box flanges, align marks
and tighten nuts to
48 Nm (35 lbf.ft).
62. Fit rear propeller shaft guard and secure with
bolts.
63. Position transmission jack under brake drum.
64. Remove 4 bolts securing LRT-99-007 to
transmission and remove support.
65. Fit transmission mounting assembly and tighten
bolts to
45 Nm (33 lbf.ft).
66. Diesel models: Fit chassis crossmember.
See
CHASSIS AND BODY, Repair.
67. Petrol models: Fit exhaust front pipe.
See
MANIFOLD AND EXHAUST SYSTEM, Repair.
68. Connect handbrake cable to lever, fit clevis pin
and secure pin with clip.
69. Fit window switch pack.
See ELECTRICAL,
Repair.
70. Diesel models: Fit starter motor.
See
ELECTRICAL, Repair.
71. Petrol models: Fit engine RH lifting eye, align
earth strap and secure with bolts.
72. Petrol models: Fit cooling fan cowl and secure
with clips.
73. Connect battery earth lead.
74. Fit and secure battery cover.
75. Fill transfer box with oil.
See SECTION 10,
Maintenance. See LUBRICANTS, FLUIDS
AND CAPACITIES, Information.
76. Fill gearbox with fluid.
See this section.