Hello, I am new to the 4x4 world and trying to get my first 4x4 driving again. I replaced the output shaft on the tranny and its corrospoding input in the Transfer case bacause the had worn due to a lack of lubrication and would not drive in foward. I fixed this problem and now now it will not drive go into any gear. When I put the rover in gear I dont feel it engage. I suspect a problem with the flex plate/Torque convertor and that the tranny pump may not be turning. has anyone had a problem installing a the torque convertor, The only other possiblility I can think of is that I installed the flexplate, shim and adapter plate wrong, but I doubt this. Any thoughts? I am going to get a transmission pressure checker and see if there is any before I drop it again, but I doubt there is any pressure. PLEASE help !! THANK YOU in advance

pulled this off my web site,

Check List for fitting ZF Autobox

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.

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.

by the way, you don't really need a pressure checker, with the engine idling just undo an oil pipe, it should come out like a hose pipe if the pump is OK, if a bit of oil just dribbles out the pump is broken,

I agree with the pump being stuffed. It is quite common to not fully seat the TC which will then destroy the pump when it all starts to spin. There should be three distinct clicks when the TC is properly seated.

Unfortunately, i know this from experience. :rolleyes:

if no oil comes pouring out, is the pump definitly bad ??? how does the TC destroy the pump?

Thanks,
James

How do I check the pump to see if it is bad, also it appears to fit together perfectly, If TC was not al the way on how could tranny mate to the engine so well? thanks,
James

How do I check the pump to see if it is bad, also it appears to fit together perfectly, If TC was not al the way on how could tranny mate to the engine so well? thanks,
James

Because it broke off the drive ears for the pump. If you read the post above he said remove one of the cooling lines and momentarily start engine to check for flow. It should gush out.
Did you pull out the torque convertor? Or could it have slipped forward?

JP

You really have to make sure it is seated properly. I've had about 0 luck installing the torque converter any other way but standing the transmission on end like Dave said. It's a real PITA when the TC slips out some when you have the transmission under the Rover and you have to pull it back out, stand it back up and start over just to make sure.