Removal and installation of automatic transmission 4.0L (Discovery 3)

Special tool

Torque Converter Seal Installation Tool 308-246

Torque Converter Support Handles 307-497 (LRT-44-010)

Removal

1.

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

Raise and support the vehicle.

2. Remove the transfer case. For more information, refer to Transfer Case - 4.0L (41.20.25.99)

3. Remove the gearbox heat shield. Remove 4 bolts.



4. Disconnect the selector cable.

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

5. Remove the transmission heat shield bracket. Remove the 4 bolts.





6. Remove the fuel line heat shield.

• Remove 2 bolts.
• Disconnect the fuel lines from the 3 clamps.

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



8.

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

Disconnect the transmission lines.

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

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

• Remove 3 Torx screws.
• Release the 2 clamps.

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

• Remove the Torx screw.
• Disconnect the electrical connector.

11. Release the transmission breather pipe clamp. Remove the bolt.



12. Unfasten the starter.

• Remove 2 bolts.
• Move the starter to the side and tie it up.

13. Disconnect the floppy disk.

• Turn the crankshaft to gain access to the bolts.
• Remove 4 bolts.

14. Remove the crankshaft position sensor (CSP).

• Disconnect the electrical connector.
• Remove the bolt.

15. Remove the plug from the access hole.



16.

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

CAUTION: Secure the transmission to a transmission jack.

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

With the help of an assistant, remove the gearbox.

• Using a transmission jack, jack up the transmission.
• Remove 8 bolts.

17. Install the torque converter holder.

18.

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

Remove the transmission from the transmission jack.

19. Remove the torque converter holder.

20. Using special tools, remove the torque converter.



21. Carefully remove and discard the torque converter fluid seal.



22. Remove the selector cable bracket. Unscrew 2 bolts.





23.

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

Remove the transmission breather pipes. Compress the retaining ring.



24. Remove the selector lever. Unscrew the nut.

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

2. Install the transmission breather pipes. Secure with a clamp.

3. Secure the selector cable bracket. Tighten the bolts to a torque of 10 Nm.

4. Using the special tool, install the new torque converter oil seal. Clean the seal guide surface.



5.

CAUTION: Make sure the torque converter is fully engaged into the oil pump drive.

Install the torque converter.

• Clean the seal contact surface.
• Remove special tools.

6. Install the torque converter holder.

7.

CAUTION: Secure the transmission to a transmission jack.

Place the transmission on a transmission jack.

8. Remove the torque converter holder.

9.

CAUTION: Apply the recommended grease to the torque converter bushing. For more information, refer to Specification

With the help of an assistant, install the gearbox.

• Clean the contact surfaces of the parts.
• Tighten the bolts to a torque of 45 Nm.

10. Install the flex plate onto the torque converter.

• Turn the crankshaft to gain access to the bolts.
• Tighten the bolts to a torque of 45 Nm.

11. Secure the transmission breather tube clamp. Tighten the bolt to a torque of 25 Nm.



12. Connect the wire harness.

• Tighten the Torx screws.
• Connect the electrical connector.

13. Connect the transmission lines.

• Clean the parts.
• Install new O-rings.
• Secure with a clamp.
• Tighten the bolt to a torque of 10 Nm.

14. Install the fuel line heat shield.

• Tighten the bolts to a torque of 10 Nm.
• Secure with clamps.

15. Install the transmission heat shield bracket. Tighten the bolts to 10 Nm.

16. Secure the selector cable.

17. Install the transfer case. For more information, refer to Transfer Case - 4.0L (41.20.25.99)

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

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

20. Install the transmission heat shield. Tighten the bolts to 10 Nm.