ZF4HP22/24EH

Installation

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.

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.

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        Box Code             Depth in mm

061                  22                                            747                  27

064                  22                                            748                  18

065                  27                                            757                  27

332                  51                                            759                  27

593                  51                                            763                  83

699                  51                                            764                  27

631                  51                                            765                  27

727                  27                                            766                  96*

728                  83                                              767                  27

740                  51                                            768                  83

741                  51                                             769                  83

742                  51                                            773                   96*

744                  18

*Note this is the depth for the standard converter.

If fitting our HD Td5 Converter please note the following instructions: –

The depth is 73.

The stock TD5 converter has 3 bolts, the new one has 4; the 4 bolts sit in a different place and it’s a little harder to access the new bolts.  We can supply a couple of parts to assist you, see related parts below and you will also need a ratchet spanner to fit the 4 converter bolts but to hold the bolts in place and create friction for the ratchet to click you will need to drill a hole in the bellhousing and use some long nose pliers to hold the bolt in place whilst you tighten it with the spanner through the normal lower access hole. There is a link on our website to a template so you know where to drill the hole.

The two tools you may require are:

1) 28mm dia hole saw, available on our website

2)   13mm ratchet spanner, available on our website

Please note this is only recommended on a tuned TD5 engine. If you put this on a stock TD5 engine it will be detrimental as the engine will not have enough power to get up to enough revs for the turbo to start working due to the lower stall speed, this results in the engine ‘bogging down’ at say 2000 rpm and very poor acceleration.

Please call if you have any other queries.