Discovery 2. Manual — part 571
AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS
44-23
REPAIRS
Cable and lever assembly - selector
$% 44.15.08
Remove
1. Remove centre console.
REPAIRS, Console - centre - automatic
models.
2. Raise vehicle on ramp.
3. Loosen selector cable trunnion nut.
4. Remove 'C' clip and release selector cable
from gearbox bracket.
5. Lower vehicle on ramp.
6. Remove sound deadener pad.
7. Remove 3 bolts securing selector lever bracket
to tunnel, remove selector lever.
8. Remove 'C' clip securing outer cable to
selector lever bracket.
9. Remove locking ring securing inner cable to
selector lever.
10. Release inner cable from selector lever,
release cable from grommet and remove cable
from selector lever bracket.
Refit
1. Position cable through grommet, align to
bracket and secure with 'C' clip.
2. Fit inner cable to selector lever and secure with
locking ring.
3. Feed selector cable through tunnel, align
bracket, fit and tighten bolts.
4. Fit sound deadener pad.
5. Fit centre console.
REPAIRS, Console - centre - automatic
models.
6. Position selector cable through trunnion and
gearbox bracket, secure with 'C' clip.
7. Adjust selector cable.
AUTOMATIC GEARBOX - ZF4HP22 - 24
44-24
REPAIRS
Selector indicator
$% 44.15.10
Remove
1. Remove knob from gear lever.
2. Release selector panel from centre console.
3. Disconnect multiplug from selector panel and
remove panel.
Refit
1. Position selector panel and connect multiplug.
2. Secure selector panel to console.
3. Fit gear lever knob.
Switch - starter inhibitor
$% 44.15.19
Remove
1. Diesel models: Remove exhaust front pipe.
SYSTEMS - Td5, REPAIRS, Pipe - front.
2. Move the selector lever to position 'P'.
3. Remove nut securing selector lever to gearbox
selector shaft and release lever.
4. Remove 2 bolts securing inhibitor switch to
gearbox.
5. Release multiplug from gearbox bracket.
6. Release inhibitor switch from selector shaft.
7. Disconnect switch multiplug and remove
switch.
Refit
1. Ensure 'P' is selected by rotating selector shaft
fully clockwise.
2. Engage 'N' by rotating selector shaft 2 detents
anti-clockwise.
3. Position inhibitor switch to selector shaft,
connect multiplug and secure multiplug to
gearbox bracket.
4. Engage switch to selector shaft, and fit but do
not tighten retaining bolts.
AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS
44-25
5. Fit tool LRT-44-011 to selector shaft.
6. Insert setting pin into tool. Rotate switch until
setting pin engages with hole in switch as
shown and tighten bolts to 10 Nm (7 lbf.ft).
7. Remove setting tool LRT-44-011.
8. Position selector lever to selector shaft and
tighten nut to 26 Nm (19 lbf.ft).
9. Diesel models: Fit exhaust front pipe.
SYSTEMS - Td5, REPAIRS, Pipe - front.
Seal - selector shaft
$% 44.15.34
Remove
1. Remove valve body assembly.
- 24, REPAIRS, Valve body assembly.
2. Remove nut securing selector shaft lever and
release lever from shaft.
3. Remove 2 bolts securing gear selector switch
to gearbox and remove switch.
4. Drift out and discard selector quadrant roll pin.
Remove selector shaft.
5. Remove selector quadrant and connecting rod.
6. Remove oil seal taking care not to damage
seal housing.
AUTOMATIC GEARBOX - ZF4HP22 - 24
44-26
REPAIRS
Refit
1. Clean shaft and seal housing.
2. Using a suitable adapter, fit new seal.
3. Position selector quadrant and connecting rod.
4. Position selector shaft and secure to quadrant
using new roll pin.
5. Fit valve body assembly.
- 24, REPAIRS, Valve body assembly.
Gearbox - convertor and transfer
gearbox - Diesel
$% 44.20.04.99
Remove
1. Release fixings and remove battery cover.
2. Disconnect battery earth lead.
3. Raise vehicle on a ramp.
4. Remove starter motor
REPAIRS, Starter motor - diesel.
5. Remove 2 upper bolts securing gearbox
housing to engine.
6. Remove bolt securing closing plate to gearbox
housing.
7. Remove exhaust front pipe.
SYSTEMS - Td5, REPAIRS, Pipe - front.
8. Remove 3 nuts securing intermediate silencer
to tail pipe.
9. Release and remove silencer from rubber
mountings.
10. Drain automatic gearbox oil.
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