| Author | Message | ||
     Colin Spencer (Colinspencer) New Member Username: Colinspencer Post Number: 5 Registered: 12-2003 |
My 96 Disco SD has some serious issues with its transmission. At 215K the ZF quit, after replacing the motor and t-case with brand new units within the last year. A transmission was installed from another disco with no success. Previous owner got fed up and, to make a long story short I inherited the disco. I've been through the car as much as I can without dropping the transmission out and I'm still baffled. My question is a broad one. So far I've checked the t-case selectors, interlock solenoids, flywheel to torque convertor bolts, fluid levels, basically everything that jumps out as being obvious. Since the transmission worked before putting it into the car I can only imagine that it must be something simple. Has anyone had a similar experience? Any feedback is appreciated. Thanks | ||
| Chris Browne (Chris_browne) Senior Member Username: Chris_browne Post Number: 675 Registered: 02-2003 |
Let me guess, you can move the selector into drive and reverse but it wont move? | ||
| John Cinquegrana (Johnc) Senior Member Username: Johnc Post Number: 624 Registered: 07-2002 |
to add to Chris' comment.... have you tried locking the diff? Could it be a bad CV? | ||
| Colin Spencer (Colinspencer) New Member Username: Colinspencer Post Number: 6 Registered: 12-2003 |
Selector moves in all positions, engine idle speed changes with the shift. No spinning of the t-case outputs in any gear configuration. The transfer case selector is apart and I just bolted the shifter back in place and loosely attatched the high-low selector. The lockout soleniod was stuck in the lock position so I had to remove it in order to shift from neutral. No power to the plug when checked with a meter. Could there be a blown fuse somewhere? any other lockouts or solenoids that could inhibit engagement? Not sure if the diff lock lever has a intermediate, where it isnt in either setting. Checked on defender t-case and it doesnt appear to have any such position. Also car wont start when in park but starts when in any other gear position. Tried all transfer case positions with no luck. Also, makes a wicked clanging noise at idle, sounds like something sheet metal, might just be the ring gear hitting against something. I'm thinking it might be something wrong with the connection between the t-case and transmission. I'm at the point where I may take the car to a transmission specialist and have him assess the problem. | ||
| Curtis N (Curtis) Dweb Lounge Member Username: Curtis Post Number: 1235 Registered: 05-2002 |
Colin, Sounds like you have likely just installed an ZF4HP22 electronic transmission in a non-electronic application. The '96 Disco S1 does not have any solenoids at all. It uses pressure regulated valves in the valve body. In later Disco II's they used the electronic version with solenoids and a Bosch transmission controller. I am not 100% sure this will work, but you may want to try putting on the valve body from your old transmission. I believe the actual transmissions are the same so you may have some luck. Still, there is no way that the electronic valve body will work. Even with the trans controller, you would need it to communicate with the ECU and I don't see that happening. Good luck. | ||
| Curtis N (Curtis) Dweb Lounge Member Username: Curtis Post Number: 1238 Registered: 05-2002 |
I just crawled under my DS2 and if the situation is what I state above then it will not work. The elctronic version does not have a kickdown cable and it appears the case is sealed in the area. If you have the electronic ZF tansmission in there you will probably have to pull it back out. Sorry. | ||
| Colin Spencer (Colinspencer) New Member Username: Colinspencer Post Number: 8 Registered: 12-2003 |
Is there any way to ID the transmission? I looked underneath and I couldnt find any kickdown cable anywhere, I also found a plug with 4 wires going into the front of the transmission. It has a brown, 2 black and a green wire, but it was pluged into a connector in the vehicles harness. I dont have the original transmission as the previous owner had all the work done before I owned it and I think the guy got rid of the unit wen he was done with it. If it is indeed a D2 transmission, is anyone intrested in it, or know where I could get a correct unit? thanks. | ||
| Curtis N (Curtis) Dweb Lounge Member Username: Curtis Post Number: 1240 Registered: 05-2002 |
The kickdown cable is on the left side just above and forward of the shift linkage. It routes to your throttle linkage above the intake plenum. If you feel an electrical connecter just above and slightly behind the shift linkage then you have the electronic one. I may have a completely rebuilt transmission available in a couple of weeks. I will warn you, these transmissions tend to be expensive. Plan on at least $2000 with core exchange. More in some cases. | ||
| Kyle Van Tassel (Kyle) Moderator Username: Kyle Post Number: 871 Registered: 11-2002 |
How do you read that Curtis ? More then likely the issue is the Transfer case.. Remove the cover from the bottom and run your tests again with someone in the truck. See if you got some shit moving around then. Dont get your ass run over.... | ||
| Curtis N (Curtis) Dweb Lounge Member Username: Curtis Post Number: 1243 Registered: 05-2002 |
I read this post a few days ago and thought the same thing at first, but the more I kept reading about solenoids and such, it just didn't add up. If he is seeing solenoids on the botom of the valve body instead of valve assemblies (and has no kickdown cable), then he has the wrong transmission in. It ain't gonna work. Colin, if you want to verify the transmission, just remove the pan and post a pic of the underside of the valve body. That will tell us for sure. | ||
| Ron Brown (Ron) Senior Member Username: Ron Post Number: 804 Registered: 04-2001 |
You can ID the trans by the number on the side. The parts book has date references. It could still be a CV, I have seen several trans and T-cases installed due to a blown cv. Ron | ||
| Colin Spencer (Colinspencer) New Member Username: Colinspencer Post Number: 9 Registered: 12-2003 |
I've looked at the transmission for a while now and there is no kickdown cable to be found, nothing attatched to the throttle linkage either. I checked what it should look like on my 93 RR LWB and it is indeed diffrent. The only electrical gadget I an see going into the transmission has the 4 wires I mentioned earlier. The manual lists this simply as "Inhibitor Switch" but doesn't give any explanation of what it does. The car only starts when the shifter is in the neutral position as well, and engine speeds up like a load is being taken off it when I shift from neutral in either directon, makes no speed changes or noises when moved into any other gear. Previous owner got the trans that is in the truck from Ebay and had a local shop install it so it could indeed be from a S2 Disco. Also several of you mentioned a bad CV, where is this located? The only cv's I know of are the ones in the front axle. Drivetrains are really my weak point as far as automatic transmissions are concerned so I'm kind of flying blind here. Thanks everyone for the help so far. | ||
| Kyle Van Tassel (Kyle) Moderator Username: Kyle Post Number: 872 Registered: 11-2002 |
All the series 1s have the interlock on them Cutis... I dont see where he is saying he dropped the pan and saw solonoids. The truck would still move either way. It just wouldnt shift. I am betting this is a T case issue. Its in neutral OR its BROKE...  Kyle | ||
| Chris Browne (Chris_browne) Senior Member Username: Chris_browne Post Number: 683 Registered: 02-2003 |
I'm with kyle on this. Looks like a Transfer box at best in neutral or worst having suffered some internal failure. If you're sure you are in Low or High, drain the transfer box and see if lost of metal bits come out..... |
