Land Rover 2000-05

Transmission Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect battery ground cable.
  4.  
  5. Raise vehicle on ramp.
  6.  
  7. Remove 8 bolts securing center crossmember and remove crossmember.
  8.  
  9. Remove front exhaust pipe.
  10.  
  11. Remove intermediate muffler from tail pipe and rubber mountings.
  12.  
  13. Drain automatic transmission fluid.
  14.  
  15. Drain transfer case oil.
  16.  
  17. Remove front and rear propeller shafts.
  18.  
  19. Remove plug from torque converter housing to access torque converter bolts.
  20.  
  21. Remove and discard 4 bolts securing torque converter to drive plate.
  22.  
  23. Remove parking brake drum.
  24.  
  25. Remove parking brake backing plate from mounting and tie aside.
  26.  
  27. Remove retaining clip holding high/low ratio selector cable to transfer case lever. Remove C-clip and remove outer cable from gearbox, as shown.
  28.  
  29. Disconnect 2 connectors from differential lock switch and multiplugs from high/low ratio switch and neutral sensor.
  30.  
  31. Remove cable tie and multiplug from bracket on transfer case.
  32.  
  33. Release transfer case and automatic transmission breather pipes from clip of rear of cylinder head.
  34.  
  35. Position transmission support jack and secure tool LRT-99-008A to support plate on transmission jack.
  36.  
  37. Position a second support jack under engine, using wooden block between oil pan and jack to prevent damage to oil pan.
  38.  
  39. Remove left side rear engine mount.
  40.  
  41. Remove right side rear engine mount.
  42.  
  43. Remove transmission oil cooler pipes from engine clips.
  44.  
  45. Unscrew transmission cooler pipe connections from transmission and remove O-rings.
  46.  


    Click image to see an enlarged view

    Fig. Showing the location of high/low ratio selector cable-Discovery (2003-04)



CAUTION
Always fit plugs to open connections to prevent contamination.

  1. Remove C-clip securing gear selector cable to transmission bracket.
  2.  
  3. Remove nut holder gear selector lever to inhibitor switch (neutral safety switch). Release lever.
  4.  
  5. Disconnect multiplug from inhibitor switch.
  6.  
  7. Loosen transmission multiplug locking ring and disconnect plug.
  8.  
  9. Lower transmission enough to access bell housing bolts. Use care not to trap any pipes or cables when lowering transmission.
  10.  
  11. Remove 14 transmission-to-engine bolts. With assistance, remove transmission from engine.
  12.  
  13. Attach a suitable strap to retain torque converter in place.
  14.  

To install:

  1. Clean transmission and engine mating faces.
  2.  
  3. Remove torque converter retaining strap.
  4.  
  5. With assistance, position transmission to engine. Install and tighten bell housing bolts to 34 ft. lbs. (46 Nm).
  6.  
  7. Connect multiplug to transmission and tighten locking ring.
  8.  
  9. Connect inhibitor switch plug. Install switch and tighten nut to 18 ft. lbs. (25 Nm).
  10.  
  11. Attach gear selector cable to transmission with C-clip.
  12.  
  13. Clean oil cooler pipe connections at transmission and install new O-rings. Tighten pipe fittings.
  14.  
  15. Attach oil cooler pipes to retaining clamps on engine.
  16.  
  17. Install both rear engine mounts. Tighten bolts and nuts to 63 ft. lbs. (85 Nm) .
  18.  
  19. Attach transmission breather pipes to bulkhead clip.
  20.  
  21. Connect multiplugs to high/low ratio switch and neutral sensor. Attach connectors to differential lock switch.
  22.  
  23. Position cable tie and multiplug to transfer case bracket.
  24.  
  25. Connect high/low ratio cable to transfer case and secure with retaining clip.
  26.  
  27. Position parking brake backing plate and tighten bolts to 55 ft. lbs. (75 Nm).
  28.  
  29. Install parking brake drum and tighten screw.
  30.  
  31. Remove bolts securing tool LRT-99-008A to transmission.
  32.  
  33. Rotate engine to align torque converter. Install new bolts and tighten to 37 ft. lbs. (50 Nm).
  34.  
  35. Install access plug over torque converter bolt hole.
  36.  
  37. Install rear, then front, propeller shafts.
  38.  
  39. Fill transfer case with oil.
  40.  
  41. Fill automatic transmission with fluid.
  42.  
  43. Position intermediate muffler to rubber mounts and to tail pipe, with new gasket, tightening nuts to 30 ft. lbs. (40 Nm).
  44.  
  45. Install front exhaust pipe.
  46.  
  47. Install center crossmember. Tighten bolts to 19 ft. lbs. (26 Nm).
  48.  
  49. Connect battery ground cable.
  50.  
  51. Install battery cover.
  52.  
  53. Check and adjust gear selector cable.
  54.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove or disconnect the following:

    Transmission fluid
     
    Cooling fan
     
    Air intake plenum
     
    Inhibitor switch connector
     
    Oxygen sensor connectors
     
    2 bolts at top of bellhousing
     
    Front and rear driveshafts
     
    Left side heat shield
     
    Place support tool LRT-44-032 on a suitable jack and support the transmission
     
    Crossmember
     
    Snubbers
     
    Lower transmission on jack
     
    High/low shift motor connector
     
    Transmission housing multi-plug connector
     
    Oxygen sensor leads at transfer case
     
    Selector lever from selector shaft
     
    Selector cable support bracket
     
    Crankshaft position sensor
     
    Front air dam
     
    Front splash shield
     
    Torque converter cover
     
    4 drive plate-to-torque converter bolts
     
    Starter motor and wire aside
     
    Oil cooler clamp
     
    Cooler lines from both sides of transmission
     
    Transmission mounting bolts
     

  6.  
  7. With the aid of a helper, support torque converter and carefully lower transmission from vehicle.
  8.  

To install:

  1. Clean all mating surfaces.
  2.  
  3. Carefully raise transmission into position, ensuring torque converter spigot and transmission engages the mounting dowels.
  4.  
  5. Install transmission bolts and tighten to 33 ft. lbs. (45 Nm).
  6.  
  7. Install new o-rings and connect the transmission cooler lines.
  8.  
  9. Install or connect the following:

    Oil cooler clamp
     
    Starter motor and tighten bolts to 33 ft. lbs. (45 Nm)
     
    4 drive plate-to-torque converter bolts and tighten to 33 ft. lbs. (45 Nm)
     
    Torque converter cover
     
    Front splash shield
     
    Front air dam
     
    Crankshaft position sensor
     
    Selector cable support bracket
     
    Selector lever to selector shaft
     
    Oxygen sensor leads at transfer case
     
    Transmission housing multi-plug connector
     
    High/low shift motor connector
     
    Snubbers
     
    Crossmember and tighten bolts to 50 ft. lbs. (68 Nm)
     
    Remove transmission jack
     
    Left side heat shield
     
    Front and rear driveshafts
     
    2 bolts at top of bellhousing and tighten bolts to 18 ft. lbs. (25 Nm)
     
    Oxygen sensor connectors
     
    Inhibitor switch connector
     
    Air intake plenum
     
    Cooling fan
     
    Negative battery cable
     
    Transmission fluid
     
    Start the engine and check for leaks.
     

  10.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Tie hood back in upright position.
  4.  
  5. Disconnect battery ground lead.
  6.  
  7. Remove engine acoustic cover.
  8.  
  9. Remove intermediate reduction drive (IRD).
  10.  
  11. Loosen gear selector cable trunnion nut.
  12.  
  13. Release clip securing selector cable to gearbox bracket, remove selector cable and collect trunnion from selector lever.
  14.  
  15. Remove 3 screws securing left side splash shield and remove shield.
  16.  
  17. Secure LRT-54-026 to drive shaft inboard joint. Using a suitable lever, release inboard joint from gearbox.
  18.  
  19. With assistance pull hub outwards and release drive shaft from gearbox.
    CAUTION
    Care must be taken not to damage oil seal when removing drive shaft from gearbox

  20.  
  21. Remove and discard circlip from end of drive shaft.
  22.  
  23. Remove 2 bolts securing torque converter access plate.
  24.  
  25. Remove access plate.
  26.  
  27. Mark drive plate to torque converter, for refit purposes.
  28.  
  29. Remove 4 bolts securing drive plate to converter.
  30.  
  31. Remove bolt securing IRD cooling hose retainer. Remove retainer.
  32.  
  33. Remove 2 bolts securing gearbox to engine.
  34.  
  35. Release HO 2 S multiplug from support bracket on left side camshaft cover, disconnect connector.
  36.  
  37. Remove 4 nuts securing left side exhaust manifold to cylinder head.
  38.  
  39. Remove exhaust manifold, remove and discard gasket.
  40.  
  41. Position container to collect fluid spillage.
  42.  
  43. Disconnect 2 fluid cooler hose unions and discard O-rings.
    CAUTION
    Always fit plugs to open connections to prevent contamination.

  44.  
  45. Remove 3 bolts securing fluid cooler bracket.
  46.  
  47. Move fluid cooler aside.
  48.  
  49. Remove bolt securing CKP sensor to gearbox, release sensor and position aside.
  50.  
  51. Remove nut and bolt, adjacent to CKP sensor, securing gearbox to engine.
  52.  
  53. Release throttle cable from abutment bracket and disconnect cable from throttle body cam, if equipped.
  54.  
  55. Depress collars and release 2 breather pipes from throttle housing, if equipped.
  56.  
  57. On vehicles with cruise control, disconnect vacuum hose from cruise control actuator.
  58.  
  59. Remove 4 Torx® screws securing throttle housing, release throttle housing and position aside.
  60.  
  61. Remove and discard O-ring from throttle housing.
  62.  
  63. Remove starter motor.
  64.  
  65. Remove bolt securing engine ground lead.
  66.  
  67. Release connectors from clips attached to fluid pan.
  68.  
  69. Disconnect 2 gearbox harness to main harness connectors.
  70.  
  71. Using a hoist, connect adjustable lifting bracket, LRT-12-138 to engine.
  72.  
  73. Raise hoist to take weight without exerting any load on the engine mountings.
  74.  
  75. Install suitable lifting brackets to gearbox and secure with nuts and bolts.
  76.  
  77. Connect lifting equipment to brackets.
  78.  
  79. Remove through bolt securing left side engine mount to gearbox bracket.
  80.  
  81. Remove 4 bolts securing left side mount to body and remove mount.
  82.  
  83. Remove 4 bolts securing left side mounting bracket to gearbox and remove bracket.
  84.  
  85. Remove 2 top bolts securing gearbox to engine.
  86.  
  87. Release gearbox from 2 dowels.
  88.  
  89. Maneuver and lower gearbox to floor.
  90.  
  91. Install converter retaining plate and secure with bolts.
  92.  

To install:

  1. Remove torque converter retaining plate.
  2.  
  3. Ensure converter is fully located in oil pump drive by checking depth 'A' as illustrated. Depth A = 0.157 inch (4mm).

    Click image to see an enlarged view

    Fig. Measuring converter depth in oil pump drive-Freelander (2000-04)

  4.  
  5. Clean gearbox to engine mating faces, dowels and dowel holes.
  6.  
  7. Install gearbox assembly.
  8.  
  9. Install bolts securing gearbox and tighten to 63 ft. lbs. (85 Nm).
  10.  
  11. Position left side mounting bracket to gearbox, fit and tighten bolts to 63 ft. lbs. (85 Nm).
  12.  
  13. Position left side mounting to body, fit and tighten bolts to 35 ft. lbs. (48 Nm).
  14.  
  15. Align gearbox bracket to left side body mounting, fit and tighten through bolt to 74 ft. lbs. (100 Nm).
  16.  
  17. Disconnect lifting equipment.
  18.  
  19. Remove nuts and bolts securing lifting brackets to gearbox and remove brackets.
  20.  
  21. Connect engine and gearbox harness connectors to main harness.
  22.  
  23. Secure connectors to clips.
  24.  
  25. Position engine ground lead and secure with bolt.
  26.  
  27. Install starter motor.
  28.  
  29. Clean throttle housing and manifold chamber mating faces.
  30.  
  31. Install new seal to intake manifold chamber.
  32.  
  33. Position throttle housing to manifold chamber, fit Torx® screws and tighten to 7 ft. lbs. (9 Nm).
  34.  
  35. Connect throttle inner cable to throttle cam and secure outer cable in abutment bracket, if equipped.
  36.  
  37. Connect hose to cruise control actuator.
  38.  
  39. Secure breather hoses to throttle housing, if equipped.
  40.  
  41. Adjust throttle cable, if equipped.
  42.  
  43. Clean CKP sensor and mating face.
  44.  
  45. Install CKP sensor, fit bolt and tighten to 7 ft. lbs. (9 Nm).
  46.  
  47. Position fluid cooler, tighten M12 bolts to 63 ft. lbs. (85 Nm) and M8 bolt to 18 ft. lbs. (25 Nm).
  48.  
  49. Clean fluid cooler unions.
  50.  
  51. Lubricate new O-rings with clean transmission fluid and fit O-rings to fluid cooler hoses.
  52.  
  53. Connect fluid cooler hoses to gearbox and tighten unions to 13 ft. lbs. (18 Nm).
  54.  
  55. Clean exhaust manifold and mating face on cylinder head.
  56.  
  57. Install exhaust manifold gasket.
  58.  
  59. Position exhaust manifold, fit nuts and progressively tighten, from center outwards to 33 ft. lbs. (45 Nm).
  60.  
  61. Connect HO 2 S multiplug and secure to support bracket.
  62.  
  63. Position IRD cooling hose retainer, fit bolt and tighten to 18 ft. lbs. (25 Nm).
  64.  
  65. Align marks on drive plate to torque converter.
  66.  
  67. Install bolts securing drive plate to torque converter and tighten bolts to 45 Nm (33 ft. lbs.).
  68.  
  69. Clean torque converter access plate.
  70.  
  71. Position access plate, fit bolts and tighten to 7 ft. lbs. (9 Nm).
  72.  
  73. Clean end of drive shaft and mating splines in gearbox.
  74.  
  75. Install new circlip to left side drive shaft.
  76.  
  77. With assistance pull hub outwards, align drive shaft and fit to gearbox, taking care not to damage drive shaft oil seal.
    CAUTION
    Pull the drive shaft to ensure the circlip is fully engaged and retains the shaft.

  78.  
  79. Install splash shield and secure with bolts.
  80.  
  81. Position trunnion to selector lever, locate inner cable through trunnion, do not tighten nut at this stage.
  82.  
  83. Position selector cable to gearbox bracket and secure with clip.
  84.  
  85. Adjust selector cable.
  86.  
  87. Install IRD.
  88.  
  89. Connect the negative battery cable.
  90.  
  91. Install engine acoustic cover.
  92.  
  93. Untie and close hood.
  94.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Fan shroud from the radiator
     
    Transmission breather pipes from the right cylinder head at the rear and the dipstick
     
    Kickdown cable from the throttle linkage
     
    Shift boot knob and boot from the center console
     
    Fluid from the transmission and the transfer case
     
    Exhaust system, from the manifolds back
     
    Speedometer from the transfer case
     
    Driveshafts at the transmission and transfer case and support them out of the way.
     
    Transmission oil cooler lines and secure them out of the way.
     
    Transmission shift cable and the wiring harness from the transmission
     

  4.  
  5. Secure a transmission jack to the transmission.
  6.  
  7. Remove or disconnect the following:

    Transmission crossmember
     
    Transfer case side mounts and mounting brackets
     
    Parking brake cable from the lever
     
    Driveplate inspection cover and matchmark the torque converter to the driveplate.
     
    Torque converter bolts and the fill tube from the transmission
     
    Bell housing to engine bolts
     

  8.  
  9. Pull the transmission rearward, slightly, secure the torque converter to the transmission.
  10.  
  11. Remove the transmission from the vehicle.
  12.  

To install:

  1. Install or connect the following:

    Transmission to the vehicle
     
    Bell housing-to-engine bolts and tighten to 31 ft. lbs. (42 Nm)
     

  2.  
  3. Align the matchmarks for the torque converter to the driveplate.
  4.  
  5. Apply Loctite® to the torque converter bolts and tighten to 29 ft. lbs. (39 Nm).
  6.  
  7. Install or connect the following:

    Fill tube to the transmission
     
    Driveplate inspection cover
     
    Parking brake cable to the lever
     
    Transfer case side mounts and tighten the bolts to 33 ft. lbs. (45 Nm).
     
    Transmission crossmember
     
    Transmission shift cable and the wiring harness to the transmission
     
    Transmission oil cooler lines
     
    Driveshafts at the transmission and transfer case
     
    Speedometer to the transfer case
     
    Exhaust system
     
    Transmission and transfer case with Dexron®II ATF
     
    Shift boot and knob
     
    Kickdown cable to the throttle linkage
     
    Transmission breather pipes to the right cylinder head at the rear
     
    Fan shroud to the radiator
     
    Negative battery cable
     

  8.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove or disconnect the following:

    Fan shroud
     
    Transmission filler tube from the engine
     
    Window switch pack
     
    Parking brake cable clevis pin
     
    Parking brake cable from the tunnel grommet
     
    Transmission and transfer case fluid
     
    Exhaust front pipe
     
    Transmission mount
     

  6.  
  7. Secure a transmission jack to the transmission.
  8.  
  9. Remove or disconnect the following:

    Front and rear driveshafts
     

  10.  
  11. Place a block of wood between the axle housing and the oil pan for support, and slightly lower the assembly.
  12.  
  13. Remove or disconnect the following:

    Gear selector cable from the transmission lever
     
    Selector cable
     
    Transmission temperature sensor wiring
     
    High/low motor wiring
     
    Speed sensor wiring
     
    Position sensor wiring
     
    Wiring harness from the clips
     
    Cooler pipe clamp bolt
     
    Cooler pipes
     
    Filler pipe from the transmission
     
    Breather pipes
     
    Converter housing cover
     

  14.  
  15. Matchmark the drive plate and converter.
  16.  
  17. Remove or disconnect the following:

    Drive plate-to-converter bolts
     
    Converter housing-to-engine bolts
     

  18.  
  19. Pull the transmission back, making sure that you don-t drop the converter.
  20.  
  21. Lower and remove the transmission/transfer case assembly.
  22.  
  23. Support the assembly, nose down, on a bench.
  24.  
  25. Remove the 6 transfer case-to-transmission bolts.
  26.  
  27. Release the 2 ring dowels and separate the transfer case from the transmission.
  28.  

To install:

  1. Clean all mating surfaces.
  2.  
  3. Support the transmission, nose down, on a bench.
  4.  
  5. Position the transfer case and ring dowels. Install the bolts and tighten them to 33 ft. lbs. (45 Nm).
  6.  
  7. Raise the assembly into position, aligning the torque converter and drive plate. Tighten the transmission-to-engine bolts to 31 ft. lbs. (42 Nm).
  8.  
  9. Install the converter-to-flexplate bolts and torque to 33 ft. lbs. (45 Nm).
  10.  
  11. Install or connect the following:

    Converter cover plate, with a new gasket
     
    Breather pipes
     
    Filler pipe
     
    Cooler lines
     
    Cooler line clamp
     
    Wiring
     
    Selector cable
     
    Transmission mount. Torque the bolts to 33 ft. lbs. (45 Nm).
     

  12.  

 
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