Repair Procedure
PERFORM VERIFICATION OF BREATHER LOCATION ON DISCOVERY SERIES IINOTE:
A precise VIN for Discovery Series II vehicles is not available for the change of breather tubes from the engine bay "shepherds crook" design to the transmission sump-mounted version rerouted by this Recall. A quick visual check should be undertaken on all vehicles to ensure that the Recall applies to the existing vehicle configuration.
1. Inspect under Discovery Series II vehicle to verify that transmission mounted breather pipe is present.
2. If no breather pipe is observed, open the hood and inspect for presence of two "shepherd's crook" design breathers (Transmission and Transfer Gearbox) along engine bulkhead behind the RH side of the engine. (Figure 1)
3. If shepherd's crook breathers for both the transmission and the transfer gearbox are present, perform the following:
^ Go to "Campaign Label Installation" and install a label for D233
^ Claim Recall D233 Option 1
POSITION BREATHER TUBE NEW VEHICLES IN RETAILER INVENTORY
UNDER 500 MILES AND NEVER WADED
1. Raise vehicle on lift.
2. Locate end of transmission breather tube clipped to the edge of the transmission pan. (Figure 1)
3. Inspect the end of the tube for blockage or damage.
4. Unfasten clip from transmission and remove the clip from the tube. Discard the clip.
5. Guide the end of the breather tube up over the top of the transmission housing.
6. Locate the white three-hole tube-locating clip near the top of the transmission housing.
7. Spray a small amount of silicon lubricant on the breather tubing near the locating clip.
CAUTION:
The orientation of the breather pipes is slightly different on Range Rover and Discovery Series II vehicles. On Discovery Series II vehicles observe the following:
^ The Transfer Gearbox breather and the Transmission breather come from opposite sides of the vehicle. Movement of the white tube locating clip is limited by the divergence of the tubes.
^ The breather is secured to an electrical harness and must be released from that restraint.
^ Care must be exercised to avoid crimping or deforming the tubing.
8. On Range Rover vehicles slide the white tube clip toward the rear of the vehicle until it stops against the bulge at the end of the repositioned drain tube. (Figure 2)
9. On Discovery Series II vehicles perform the following:
^ Snip the cable tie to release the breather tube from the electrical harness.
^ Slide the white tube clip toward the rear of the vehicle until resistance is met because of the divergence of the transmission and transfer box tubes. (Figure 3)
^ Verify that the end of the breather tube is parallel with the AT breather and pointed toward the LH rear of the vehicle.
10. Wipe any residual silicon lubricant from tubes.
11. Go to "Campaign Label Installation" and install a label for D233
12. Claim Recall D233 Option 2
PERFORM PARK LOCK TEST
CAUTION:
Every test must be carried out on a slope selected so that the vehicle will roll slowly forward with the transmission selector in the "N" neutral position. Ensure that no obstruction or object will interfere with testing.
1. Check the park lock function as follows:
^ Position vehicle on a slight forward down slope.
^ Start the engine, place the transmission in "N" neutral and allow the vehicle to roll forward no more than two meters (6 feet).
^ Stop the vehicle completely using the foot brake and select "P" park.
^ Release the foot brake and check that the vehicle does not roll forward.
^ Repeat this procedure nine more times.
2. If the park lock fails to hold on any of the ten tests, go to "REPLACE TRANSMISSION" section of this TIB.
3. If the park lock holds in all ten tests, go to the "Position Breather Tube and Test Fluid for Contamination" section of this TIB.
REPLACE TRANSMISSION
1. Refer to Service Bulletin SWA00-06. Contact ZF at 201 573 7709 following normal automatic transmission replacement procedures.
2. Remove transmission with park lock failure and install a replacement transmission following the procedures in RAVE, Section 44.20.04.99.
3. Flush transmission cooler and cooler lines prior to installation of the replacement transmission.
4. Route the breather tube during transmission installation as follows:
^ Locate end of transmission breather tube and inspect the end of the tube for blockage or damage.
^ Guide the end of the breather tube up over the top of the transmission housing.
^ Locate the white three-hole tube-locating clip near the top of the transmission housing.
^ Spray a small amount of silicon lubricant on the breather tubing near the locating clip.
CAUTION:
The orientation of the breather pipes is slightly different on Range Rover and Discovery Series II vehicles. On Discovery Series II vehicles observe the following:
^ The Transfer Gearbox breather and the Transmission breather come from opposite sides of the vehicle. Movement of the white tube-locating clip is limited by the divergence of the tubes.
^ The breather is secured to an electrical harness and must be released from that restraint.
^ Care must be exercised to avoid crimping or deforming the tubing.
5. On Range Rover vehicles slide the white tube-locating clip toward the rear of the vehicle until it stops at the end of the repositioned drain tube. (Figure 2)
6. On Discovery Series II vehicles perform the following:
^ Snip the cable tie to release the breather tube from the electrical harness.
^ Slide the white locating tube clip toward the rear of the vehicle until resistance is met because of the divergence of the transmission and transfer box tubes. (Figure 3)
^ Verify that the end of the breather tube end is parallel with the outgoing AT breather tube and pointed toward the LH rear of the vehicle.
7. Wipe any residual silicon lubricant from tubes.
8. Go to "Campaign Label Installation" and install the label.
9. Claim Recall D233 Option 5, 6, or 7 depending on the vehicle serviced.
POSITION BREATHER TUBE AND TEST FLUID FOR CONTAMINATION
1. If the park lock holds in all ten tests, raise vehicle on lift.
2. Locate end of transmission breather tube clipped to the edge of the transmission pan. (Figure 4)
3. Inspect the end of the tube for blockage or damage.
4. Unfasten clip from transmission.
5. Guide the end of the breather tube up over the top of the transmission housing.
6. Locate the white three-hole tube-locating clip near the top of the transmission housing.
7. Spray a small amount of silicon lubricant on the breather tubing near the locating clip.
CAUTION:
The orientation of the breather pipes is slightly different on Range Rover and Discovery Series II vehicles. On Discovery Series II vehicles observe the following:
^ The Transfer Gearbox breather and the Transmission breather come from opposite sides of the vehicle. Movement of the white tube-locating clip is limited by the divergence of the tubes.
^ The breather is secured to an electrical harness and must be released from that restraint.
^ Care must be exercised to avoid crimping or deforming the tubing.
8. On Range Rover vehicles slide the white locating tube clip toward the rear of the vehicle until it stops against the bulge at the end of the repositioned drain tube. (Figure 1)
9. On Discovery Series II vehicles perform the following:
^ Snip the cable tie to release the breather tube from the electrical harness.
^ Slide the white locating tube clip toward the rear of the vehicle until resistance is met because of the divergence of the transmission and transfer box tubes. (Figure 2)
^ Verify that the end of the breather tube is parallel with the outgoing AT breather and pointed toward the LH rear of the vehicle.
10. Wipe any residual silicon lubricant from tubes.
NOTE:
The fluid testing process must be followed carefully to avoid unnecessary loss of AT fluid. Done with care and with the proper tools, approximately 100 cc (3-4 oz.) of fluid can be drained for evaluation. You must have approximately two inches of fluid in the bottom of your container when the fluid sample is taken.
WARNING:
Fluid drained from the sump pan may be "hot". Exercise care when draining the fluid.
11. Test the fluid to determine the presence of water contamination as follows:
^ Obtain a clean, clear glass container about three inches in diameter and about 6 inches tall.
^ Using a 5 mm Allen wrench, break the seal on the transmission drain plug.
^ Orient the Allen wrench with the long portion vertical and carefully unscrew the plug until AT fluid seepage is observed.
^ Hold the container under the plug opening and carefully unscrew the plug until no threads are engaged but maintaining pressure against the opening.
^ Tilt the plug slightly to drain the fluid sample required to give 1.5 to 2 inches of fluid in the bottom of the container.
^ Thread the plug back into the opening reusing the original seal.
Torque the plug to 15 Nm (11 lbf.ft.).
NOTE:
If a level of uncertainty exists as to the correct appearance of the sample, a comparison of the sample taken to new fluid from stock will be helpful.
12. Visually inspect the fluid for the presence of water contamination against the following parameters:
Uncontaminated fluid will have a bright red appearance and will be "clear". You can easily see your finger on the bottom of the clear container from the top through the 2 inches of drawn fluid.
^ Lightly contaminated fluid will have a deep burgundy red color and cloudy appearance.
^ Heavily contaminated fluid will have a "milky pink" appearance.
13. If the transmission fluid is clear, perform the following:
Top up the transmission fluid level to the correct level making sure to follow the procedure outlined in TIB 44/01/99/NAS.
Install the campaign label as outlined in the "Campaign Label Installation" section of this TIB.
^ Claim Recall Option 3.
14. If the transmission fluid exhibits a contaminated appearance, drain and flush the transmission using the method specified in the next section.
DRAIN AND FLUSH TRANSMISSION
WARNING:
Fluid drained from the sump pan may be "hot." Exercise care when draining the fluid.
NOTE:
Fluid will remain in the torque converter, therefore only 5 liters of fluid can be drained at any one time.
1. Drain the fluid from the transmission.
2. Remove the oil pan and strainer.
3. Clean out all debris and sludge from the pan using a lint free cloth.
4. Refit old strainer and pan using the original seal.
CAUTION:
Additional fluid will need to be added to the transmission after the engine has been started to bring the fluid to approximately the correct level.
WARNING:
Ensure wheel chocks are set during the following procedure and hand brake and foot brake are applied when selecting gears.
5. Fill the transmission with new fluid.
6. Carry out the flushing process as follows:
^ Start and run the engine.
^ Select all gears twice and then select neutral "N" position.
^ Add fluid as described in TIB 44/01/99/NAS to obtain proper fluid level.
^ Run the engine for 20 minutes
^ Switch off engine.
WARNING:
Fluid drained from the sump pan may be "hot." Exercise care when draining the fluid.
7. Check the water content of the transmission fluid again as described in "Position Breather Tube and Test Fluid for Contamination."
8. If the fluid is still contaminated go to Step 1 of this section and flush as many times as required until the fluid is clear.
9. When the fluid checked is clear, perform the following:
^ Drain the fluid from the transmission.
^ Remove the sump pan and discard the pan seal.
^ Remove the strainer and discard.
^ Wipe out the sump pan with a lint free cloth to remove any residual debris and sludge.
^ Fit new strainer with O-ring and tighten retaining screws to 8 Nm (71 lbf.in.).
^ Install new sump pan seal.
^ Install the pan to the transmission and tighten fasteners to 8 Nm (71 lbf.in.).
10. Fill the transmission with the correct quantity of fluid up to the level plug.
11. Start and run the engine.
12. Check fluid level as described in TIB 44/01/99/NAS to obtain proper fluid level.
13. Road test the vehicle to verify that the transmission functions correctly.
14. Install the campaign label as outlined in the "Campaign Label Installation" section and claim Recall Option 4.
CAMPAIGN LABEL INSTALLATION
NOTE:
Campaign labels may have multiple campaign numbers written on them if multiple campaigns are performed at the same time.
1. When all specified repairs have been accomplished, prepare the campaign label (LRN0002LABEL) as follows:
a) Place the label on a hard surface.
b) Use a ballpoint pen to neatly write/scribe in the bare aluminum areas of the label the following information:
^ Campaign code performed ("D233")
^ Your Retailer code
^ The date of repair
2. Peel the label back, apply to radiator support and roll the label with the special roller.