Removal and installation of automatic transmission 2.7L (Discovery 3)

Special tool

Adapter for key 303-1069

Removal

1. Disconnect the ground cable from the battery. For more information, refer to Specification.

2.

CAUTION: Never work on a vehicle supported solely by a jack. Always support the vehicle securely.

Raise and support the vehicle.

3. Remove the front propeller shaft. For more information, refer to Front Propeller Shaft - 2.7L Diesel (47.15.02)

4. Remove the exhaust system. For more information, refer to Exhaust System - Vehicle does not include: Diesel Fuel Filter (10/30/08)

5. Remove the rear propeller shaft. For more information, refer to Rear Propeller Shaft (47.15.03)

6. Remove the starter. For more information, refer to Starter (86.60.01)

7. Disconnect the selector cable.

• After securing the clamping sleeve with an additional key, loosen the lock nut.
• Press the lock and release the cable.

8. CAUTION: To avoid contamination of the system, always plug all open connections.



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Disconnect the transmission lines.

• Remove the bolt.
• Release the clamp.
• Remove and discard the 2 O-rings.

9. Remove the turbocharger support bracket. Unscrew the nut and remove the 2 bolts.



10. Remove the exhaust system heat shield. Unscrew the 7 nuts.



11. Remove the left exhaust bypass pipe support bracket.

• Remove 3 bolts.
• Disconnect the transmission wiring harness.

12. Remove the right exhaust bypass pipe support bracket. Remove 3 bolts.



13. Remove the exhaust bypass pipe center support bracket. Remove 2 bolts.



14. Disconnect the wiring harness from the left side of the gearbox.

• Remove 2 bolts.
• Release the clamp.

15. Disconnect the wiring harness from the right side of the gearbox.

• Remove the bolt.
• Disconnect the electrical connector.

16. Disconnect the transfer case electrical connectors. Disconnect the 3 electrical connectors.



17.

CAUTION: To avoid contamination of the system, always plug all open connections.

NOTE: For clarity, the gearbox is shown removed.

Disconnect the breather pipe. Compress the retaining ring.



18. Disconnect the wiring harness from the transfer case.

• Remove 3 bolts.
• Release the clamp.

19. Remove the radiator access panel. Remove 4 bolts.



20. Disconnect the floppy disk.

• Remove the plug from the access hole.
• Turn the crankshaft clockwise to access the mounting bolts.
• Remove 4 bolts.

21. Using a transmission jack, jack up the transmission.

22.

CAUTION: Secure the transmission to a transmission jack.

CAUTION: Support the engine. The engine will move forward when the transmission is removed.

CAUTION: Make sure the torque converter is not disconnected from the transmission.

NOTE: For clarity, the gearbox is shown removed.

With the help of an assistant, remove the gearbox. Unscrew the 15 gearbox mounting bolts.



23. Using a suitable tool, secure the torque converter.

24.

NOTE: Do not perform further disassembly if the part is removed only for access.

Remove the transmission from the transmission jack.

25. Drain the oil from the gearbox.

26. With the help of an assistant, remove the transfer case.

• Remove 8 bolts.
• Remove and discard the sealing ring.

27. Remove the selector cable bracket. Unscrew the bolts.





28. Remove the selector lever. Unscrew the nut.



29. Disconnect the fuel filter housing and support bracket.

Installation

CAUTION: If the automatic transmission fluid is very dirty or contains metallic particles, install a new transmission fluid cooler and new lines at the same time as the new transmission.

1.

NOTE: Clean the mating surfaces of the components.

NOTE: Install a new O-ring.

With the help of an assistant, install the transfer case.

• Lubricate the input shaft splines with Weicon TL7391 grease.
• Screw in 8 bolts.
• Using the special tool, tighten the bolts to a tightening torque of 45 Nm.

2. Secure the selector lever. Tighten the nut to a torque of 12 Nm.



3. Secure the selector cable bracket. Screw in 2 bolts and tighten them to 10 Nm.

4. Secure the wiring harness to the gearbox.

• Repeat the above procedure on the other side.
• Tighten the bolt to 10 Nm.

5. Using a suitable tool, secure the torque converter.

6. Place the transmission on the transmission jack.

7. Remove the torque converter holder.

8.

NOTE: Apply recommended grease to the torque converter bushing.

NOTE: Clean the mating surfaces of the components.

Install the gearbox with an assistant. Tighten the 15 bolts to 45 Nm.

9. Connect the breather pipe.

10. Secure the wiring harness to the gearbox.

• Connect the electrical connector.
• Tighten the screws.
• Secure the wiring harness to the gearbox.

11.

NOTE: Clean the mating surfaces of the components.

NOTE: Install new O-rings.

Connect the transmission lines.

• Secure the transmission fluid lines to the clamp.
• Tighten the bolt to 10 Nm.

12. Install the flex plate onto the torque converter.

• Turn the crankshaft to gain access to the bolts.
• Install the plug of the technological hole.
• Tighten the 4 bolts to 45 Nm.

13. Install the starter. For more information, refer to Starter (86.60.01)

14. Install the radiator access panel. Screw in and tighten the 4 bolts to 10 Nm.

15. Secure the exhaust gas bypass pipe central support bracket. Tighten the bolts to 25 Nm.

16. Install the right exhaust bypass pipe support bracket.

• Align the exhaust bypass pipe assembly support bracket.
• Tighten the bolts to 25 Nm.

17. Install the left exhaust bypass pipe support bracket.

• Tighten the bolts to 25 Nm.
• Secure the transmission wiring harness to the support bracket.

18. Install the exhaust system heat shield.

19. Install the turbocharger support bracket. Tighten the nut and 2 bolts to 22 Nm.

20. Install the rear propeller shaft. For more information, refer to Rear Propeller Shaft (47.15.03)

21. Install the front propeller shaft. For more information, refer to Front Propeller Shaft - 2.7L Diesel (47.15.02)

22. Install the exhaust system. For more information, refer to Exhaust System - Vehicle does not include: Diesel Fuel Filter (10/30/08)

23.

NOTE: Do not fully tighten the lock nut at this stage.

Connect the selector cable to the gearbox.

• Secure the inner cable into the lever clamp sleeve.
• Secure the selector cable to the support bracket.

24. Adjust the selector cable. For more information, refer to Adjusting the Gear Selector Cable (44.30.04)

25. Connect the ground cable to the battery. For more information, refer to Specification.

26. Check the fluid level in the transfer case and top up if necessary.

27. Check the transmission fluid level and top up if necessary. For more information, refer to Checking the Transmission Fluid Level (44.24.06)

28. Lower the vehicle.