Automatic Discovery 1

[1997 Discovery]

Hello All,

My 1997 Discovery Auto is not changing gear from a cold start only.

It has been doing it for a short while. I recently had the oil intercooler for the gearbox as well as the oil cooler pipes as they had pretty much had it, but it has not made any improvement.

There is also an oil leak coming from the engine, though I do not know where it is coming from at the moment.

Just seeing if anyone has any thoughts, before I take it to a garage again.

Last year it did have a flex plate, as the old one had broken, and also a torque converter replaced, as when the flex plate broke it also broke small spindle on the torque converter. Could this of done more serious damage.

If the cost of this repair out weighs the cost of the Discovery I may well end up with just living with this fault, as it will most likely a garage that carries out this type of repair.

Still any suggestion would be appreciated.

Thanks

Nigel

 

[RichardH]

Is the gearbox oil level ok? Did you check with the engine running, engine cold, run through all gears etc.

Was the oil changed then the cooler was done? Also the filter in the gearbox sump?

 

[1997 Discovery]

Thank you for replying.

Yes all the gear box levels are fine, they were done when I had the flexi plate etc repaired and now again with the oil cooler yesterday.

It had been doing it before the oil cooler parts were replaced, as I was hoping that would resolve the problem, but it didn't.

I can not remember though if the fault was there before the flexi plate and torque converter replaced though

 

[haigy]

My old auto used to hold on to gears when cold. Then would change.it does this to warm the oil up quicker.

Have you changed filter in the box. They arent the worse job to change just a long job so garage would b3 expensive id guess 150 for 2nd hand box the bout 200 to 400 labour

 

[1997 Discovery]

But I am doing 35mph in first gear at around 4-5000 RPM

 

[haigy]

Bloody hell. You done the change thru all gears thing to get it flushed thru everything.

 

[discool]

Copied from Ashcroft's site.

I have a 4 speed ZF Auto and it sticks in first gear in the morning or when cold and is reluctant to change up from 1st gear. Once the gearbox has warmed up it shifts normally. Why?

The governor valve is sticking, which can be caused by contamination. i.e. clutch plates or other parts disintegrating. The fine debris finds its way past the filter and tends to accumulate in the governor, causing it to stick. A temporary solution is to remove and clean the governor. The problem will often recur as debris from damaged parts continues to build up in the governor. If the problem continues after cleaning the governor then it may be necessary it replace your Autobox.
We have noticed many customers reporting this fault starting a few days after an oil and filter change and after researching this using our experience and the expertise of others in the trade we have come to the conclusion that as ATF oil is a detergent type oil, when the oil is changed this will dislodge and stir up settled debris in the autobox which in turn jams the governor valve. In light of this although it sounds controversial it is debateable if changing the oil and filter is a good idea, some say if the box it going to fail it will fail if the oil is good or bad and their advice is leave it alone. I am still undecided but the truth is I get a lot of calls from customers thinking they are looking after the autobox by servicing it and a few days later this fault occurs.

 

[1997 Discovery]

Thank you for the reply and suggestion.

I have not heard of a governor, is it something that can be removed and cleaned easily.

My mechanical skills are growing but I am really a novice, but willing to try if advise given.

Many thanks

 

[haigy]

I never changed the filter just the oil in mine.mine blew the clutch plates and was advised to change box as to change just the clutch.i fitted another box and torque converter and flywheel and all was gd for a bit but heavy offroading and towing didnt help.

 

[1997 Discovery]

Not done laning or towing in a while now

 

[haigy]

Best try the govenor then or another gearbox. Or run the box youve got in to the ground then change

 

[1997 Discovery]

How do I clean the governor as never heard of it before .

Not sure if my disco is worth a new gear box to be fair as the injector pump has been on the way out for a while to

 

[discool]

First you will have to remove the transfer box, you need download a copy of the RAVE manual, there's at least two pages in the manual on removal service/replacement of the govenor and its mounting block, so far to much to list here, but below is just some of the work involved..

GOVERNOR ASSEMBLY
Service repair no - 44.22.01
Remove
1. Remove transfer gearbox. See TRANSFER
GEARBOX, Repair, LT230T Transfer Gearbox
2. Drain oil from automatic gearbox.
3. Remove bolts securing left hand mounting
bracket to extension housing and withdraw
bracket.
4. Remove transfer gear lever housing securing
bolts and move housing aside.
5. Remove extension housing ensuring seal is not
damaged, remove and discard gasket.
6. Remove extension shaft retaining bolt, withdraw
shaft and discard ’O’ ring seal. If Tdi vehicle
remove spacer.
7. Remove governor assembly.
8. Remove park gear from governor assembly.
9. Detach governor housing.
10. Remove security clip and counter weight.
11. Remove and discard ’O’ ring seal from output
shaft and three seal rings from ’F’ clutch
housing.
12. Clean all components.
13. If necessary detach parking pawl by removing
guide plates and withdrawing mechanism.
Refit
14. Refit parking pawl mechanism if removed.
15. Fit and lubricate new seal rings to ’F’ clutch
housing shaft, ensure they are correctly seated.
16. Apply petroleum jelly to a new ’O’ ring seal. Fit to
output shaft
17. Fit park gear to governor assembly tightening
screws to correct torque.
18. Fit governor assembly to output shaft.
19. Fit extension shaft with spacer if Tdi. Fit new ’O’
ring under bolt head.
20. Fit extension housing, avoid damaging seal.
Tighten to 23 Nm.
21. Refit transfer gear lever housing to extension
housing.
22. Refit mounting bracket to extension housing.
Tighten to 52 Nm.
23. Refit transfer gearbox. See TRANSFER
GEARBOX, Repair, LT230T Transfer Gearbox
24. Refill automatic gearbox with correct grade of oil.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended

 

[1997 Discovery]

Yeah that be a garage job

 

[1997 Discovery]

Haven't had anything done so far, as the MOT is on the 16th December.

But I would thought I would post this question. Would a slipping torque converter cause the same issue of the gears not changing up?

Reason I ask recently the car has been producing a fair amount of smoke inside the car, coming from the transmission tunnel. I have checked oil levels and they are fine.

I am guessing what with the possiable issues further back in this post, and the possibility of a torque converter issue, it may be just mean getting a refurbished gear box which will have everything included and sorted.

 

[discool]

I expect the 'tester' could refuse to get into the vehicle if there's that much smoke inside.

 

[1997 Discovery]

Only really happens at 50mph or when the kick down is used for hard revving

 

[jamesmartin]

you dont need to drain auto box to clean or replace governor,which is quite an easy job (apart from removing t/box)as its sits on its own in rear housing so you dont disturb the rest of the box,it is the usual fault after oil change,especially if oil has been changed regularly which is best prevention, another oil change has know to sort the fault at times

 

[1997 Discovery]

Would this be causing the smoke though, as that more important to sort now

 

[jamesmartin]

Haven't had anything done so far, as the MOT is on the 16th December.

But I would thought I would post this question. Would a slipping torque converter cause the same issue of the gears not changing up?

Reason I ask recently the car has been producing a fair amount of smoke inside the car, coming from the transmission tunnel. I have checked oil levels and they are fine.

I am guessing what with the possiable issues further back in this post, and the possibility of a torque converter issue, it may be just mean getting a refurbished gear box which will have everything included and sorted.

not the tc
smoke ? exhaust leaking would be more likely