Check List for fitting ZF Autobox
Please note that a good 50% of our "warranty returns" are due to two basis 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.
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 and once home to do a dimensional check to confirm this using the list below showing the autobox code and the height you are looking for measured from the bellhousing face to the torque converter feet or 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.
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.
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.
non dipstick type autoboxes, TD5 Etc :
put transfer case in neutral
remove oil filler level plug, front face of oil sump,
fill until it overflows,
start engine, quickly pump more oil in until it overflows
move the gear stick up and down a few seconds in each gear whilst topping the oil level up,
once level has stabilised, test drive and recheck oil level,
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
Please call if you have any other queries.
