A/T - Fluid Leaks From Torque Converter
No: 44/02/00/NAS*Ref:
Issue: 2*
Date: 06/15/01
Transmission Oil Leak
AFFECTED VEHICLE RANGE:
Range Rover 4.6 (LP) All up to Transmission # 288455
Range Rover 4.0 (LP) All up to Transmission # 1804335
Discovery Series II (LT) All up to Transmission # 1804335
Discovery (LJ) All
Defender (LD) All
* indicates updated information
SITUATION:
OIL LEAK IN TORQUE CONVERTER OR INTERMEDIATE PLATE AREA
A transmission oil leak might develop in the torque converter or intermediate plate area. The cause may be oil seepage through the thread of bell housing mounting bolts.
RESOLUTION:
SEAL BOLT THREADS AND INSTALL NEW GASKET
Replace the intermediate plate gasket and apply Loctite(R) 243 to five of the bell housing mounting bolts as specified in the Procedure section of this TIB.
PARTS INFORMATION:
RTC4320 GASKET Qty 1
LRN24078 Loctite 243 Sealant & Thread locker
WARRANTY CLAIMS:
*NOTE:
On any Transmission exhibiting these symptoms AFTER the transmission numbers listed above ensure the ATER is completed and that the ZF HelpLine has been consulted for a repair authorization.
No authorization is required on transmissions included in the "Affected Vehicle Range" listing above.*
44.20.11 Time 6.35 hrs. Range Rover Classic
Time 5.95 hrs. Discovery
Time 7.50 hrs. Defender 90
Time 6.40 hrs. Discovery Series II
Reseal bell housing/intermediate plate mounting bolts on 4HP-22
44.20.11 Time 6.90 hrs. Range Rover 4.0/4.6 up to 1998
Time 7.30 hrs. Range Rover 4.0/4.6 1999 and up
Reseal bell housing/intermediate plate mounting bolts on 4HP-24
FAULT CODE: N
Normal warranty policy and procedures apply
REPAIR PROCEDURE
1. Refer to the WSM Section 44.20 and remove the transmission from the vehicle.
2. Remove the torque converter.
CAUTION:
The 6 bolts that mount the bell housing to the intermediate plate must remain installed.
3. Remove the 12 bolts that hold the bell housing/intermediate plate assembly to the transmission case.
CAUTION:
The input shaft and clutch A assembly must not be disturbed in the following steps.
4. Carefully remove the bell housing/intermediate plate assembly.
5. Remove the old intermediate plate gasket
NOTE:
A light coat of Vaseline may be used to hold the gasket and end-lay adjustment shim in position during assembly.
6. Place the new gasket (RTC4320) on the intermediate plate.
7. Place the transmission endplay adjusting shim on the intermediate plate stator shaft.
CAUTION:
Loctite 243 will work only when applied to an oil free surface.
NOTE:
Some of the bell housing/intermediate plate mounting bolts might have Hylomar applied to the thread.
8. Clean the threads of all mounting bolts.
9. Clean all Hylomar and all oil residues from the threads in the transmission housing.
10. Install the bell housing/intermediate plate assembly.
11. Apply a moderate amount of Loctite 243 to the threads of 5 mounting bolts.
12. Refer to Figure 1 and install the 5 bolts in the location shown.
13. Install the rest of the mounting bolts.
14. Tighten all bolts hand tight, then torque to 46 Nm (34 lbf.ft.).
CAUTION:
Care must be taken when installing the torque converter to avoid damage to the pump seal or pump drive gear. In this procedure there is no need to replace the pump shaft seal.
15. Carefully install torque converter.
16. Install the transmission into the vehicle following WSM procedures.