hi, I'm currently in the process of replacing the rear oil seal on my td5 auto on an 04. Having never done this on an auto before I was wondering what I need to know about removing and refitting the torque converter and drive plate. the gearbox is already off, if anyone could gie me any pointers that would be great cheers
sierrafery
Well-Known Member
From Ashcroft's site:
"
Check List for fitting ZF Autobox
Please note that a good 50% of our "warranty returns" are due to two basic installation errors.
1) Debris and contamination in the oil cooler and oil cooler lines, even if you have flushed them out this is no guarantee they are clean, if the old box has suffered a bad failure you would be wise to replace these.
2) Broken oil pump, by not fitting the torque converter correctly, read below.
Assembly
Check engine to bellhousing and Autobox to transfer case dowels are all fitted.
It is very important that you locate and install your torque converter correctly. One of the most common causes of failure is the torque converter not being located correctly onto the pump before fitting causing the pump to be broken on start up.
To avoid this we would suggest that you stand the autobox upright and lower the torque converter into the bellhousing.
When the torque converter has fully located onto the pump it is essential to then measure the distance from the bellhousing front face to the torque converter feet ( also known as the flange that the flexplate is bolted to).
Once the torque converter is inserted and checked make sure it does not fall forward when offering the autobox up to the engine. Do not be tempted to pull the gearbox into position with the bellhousing bolts, it should fully locate on the engine with no gap between the bellhousing and engine block.
With the autobox fitted to the engine, check that the converter will rotate freely and has a small amount (about 2mm) of end float. Bolt the converter to the flex plate using loctite or similar on the thread of the bolts.
Ensure the breather vents well away from the exhaust.
Oil Fill
Always use a good quality oil, preferably a Dextron III or similar. Put the transfer case in neutral and fill. Start the engine, the oil level will drop immediately, top back up straight away. Move the shifter lever up and down through the gears slowly whilst checking the oil level and topping up as required. Once the level has stabilised, put the transfer case in gear and the unit should now be picking up drive, this is indicated by the engine revs dropping when put in Drive.
Set up
If the vehicle is a Disco I or Range Rover Classic under no circumstances drive with the kickdown cable disconnected, as this will cause premature autobox failure.
Ensure that the shift assembly is set correctly and full travel of the shifter and engagement of all gears is positive, partial shift will cause premature autobox failure.
If the vehicle is a Disco I or Range Rover Classic you may want to adjust the kickdown cable if you want to fine tune the shift pattern, the looser the cable the softer and earlier the shifts, the tighter the cable, the harder and later the shifts.
Torque Converter Depth Table
The box code is the last 3 digits of the second number down on the name plate on the left hand side of the autobox.
Box Code.....................Depth in mm
061................................... 22
064....................................22
065....................................27
332....................................51
593....................................51
699....................................51
727....................................27
728....................................83
740....................................51
741....................................51
742....................................51
744....................................18
748....................................18
747....................................27
757....................................27
759....................................27
763....................................83
764....................................27
765....................................27
766....................................96
767....................................27
768....................................83
769....................................83
773....................................96"
"
Check List for fitting ZF Autobox
Please note that a good 50% of our "warranty returns" are due to two basic installation errors.
1) Debris and contamination in the oil cooler and oil cooler lines, even if you have flushed them out this is no guarantee they are clean, if the old box has suffered a bad failure you would be wise to replace these.
2) Broken oil pump, by not fitting the torque converter correctly, read below.
Assembly
Check engine to bellhousing and Autobox to transfer case dowels are all fitted.
It is very important that you locate and install your torque converter correctly. One of the most common causes of failure is the torque converter not being located correctly onto the pump before fitting causing the pump to be broken on start up.
To avoid this we would suggest that you stand the autobox upright and lower the torque converter into the bellhousing.
When the torque converter has fully located onto the pump it is essential to then measure the distance from the bellhousing front face to the torque converter feet ( also known as the flange that the flexplate is bolted to).
Once the torque converter is inserted and checked make sure it does not fall forward when offering the autobox up to the engine. Do not be tempted to pull the gearbox into position with the bellhousing bolts, it should fully locate on the engine with no gap between the bellhousing and engine block.
With the autobox fitted to the engine, check that the converter will rotate freely and has a small amount (about 2mm) of end float. Bolt the converter to the flex plate using loctite or similar on the thread of the bolts.
Ensure the breather vents well away from the exhaust.
Oil Fill
Always use a good quality oil, preferably a Dextron III or similar. Put the transfer case in neutral and fill. Start the engine, the oil level will drop immediately, top back up straight away. Move the shifter lever up and down through the gears slowly whilst checking the oil level and topping up as required. Once the level has stabilised, put the transfer case in gear and the unit should now be picking up drive, this is indicated by the engine revs dropping when put in Drive.
Set up
If the vehicle is a Disco I or Range Rover Classic under no circumstances drive with the kickdown cable disconnected, as this will cause premature autobox failure.
Ensure that the shift assembly is set correctly and full travel of the shifter and engagement of all gears is positive, partial shift will cause premature autobox failure.
If the vehicle is a Disco I or Range Rover Classic you may want to adjust the kickdown cable if you want to fine tune the shift pattern, the looser the cable the softer and earlier the shifts, the tighter the cable, the harder and later the shifts.
Torque Converter Depth Table
The box code is the last 3 digits of the second number down on the name plate on the left hand side of the autobox.
Box Code.....................Depth in mm
061................................... 22
064....................................22
065....................................27
332....................................51
593....................................51
699....................................51
727....................................27
728....................................83
740....................................51
741....................................51
742....................................51
744....................................18
748....................................18
747....................................27
757....................................27
759....................................27
763....................................83
764....................................27
765....................................27
766....................................96
767....................................27
768....................................83
769....................................83
773....................................96"
Bobdog
Well-Known Member
hi mate, how was your flex plate? mine had the two radial cracks and was also cracked all round the bolts. it only had a few more miles left in it if the gearbox hadnt died first anyway lolThanks for this!
Helped me a great deal.. all back together running nicely now!
