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Thread: ZF4HP22 do it yourself overhaul

  1. #1
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    ZF4HP22 do it yourself overhaul

    Ok over the next few months will be overhauling my transmission I have now received the kit from the states for about $350 AD with a modified clutch pack with extra friction disc and stronger clutch material.

    As I only sort of getting every second weekend off and live in one city and work in another this will take awhile I will not know what hard parts are needed till I strip the trans down but suspect I will need to replace the input shaft as this can cause the cross leakage into the A clutch pack causing partial engagement.

    Also trying to source a ZF4HP24 donor trans to change out the centre of mine for the stronger 24 centre but will see how that goes.
    Attached Images Attached Images
    disco seriesII mods so far:-bullbar,hyd winch,
    detriot locker,lsd front,C.D.L kit,chipped and bigger intercooler,2" lift,rock sliders, lsd in transfer case, modified auto trans.

    In the event of nuclear war,Disregard this message

  2. #2
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    Have bought this tool on eBay to make it easier to strip the clutch packs and am in process of making a clamp to mount the transmission onto a engine stand to make it easier to work on.
    Attached Images Attached Images
    disco seriesII mods so far:-bullbar,hyd winch,
    detriot locker,lsd front,C.D.L kit,chipped and bigger intercooler,2" lift,rock sliders, lsd in transfer case, modified auto trans.

    In the event of nuclear war,Disregard this message

  3. #3
    lewy is offline Wizard Silver Subscriber
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    looking forward to following this as i will be in the same boat soon i expect.nearly 300000 ks

  4. #4
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    Stevo, I installed an Ashcroft rebuilt zf, having them install the 24 c1/c2 clutch and planetary gear set.

    Dave reckoned at the time he would be happy to sell these 24 items to home rebuilders. Bit expensive, but there if you can't get a 24 box to scavenge from.

    Ashcroft Transmissions

    Lewy, when you've practiced on yours you can rebuild one of mine If you can do it yourself it does save an lot of money. Local Darwin entity wanted $6k for the whole job - is why I went Ashcroft in the end. My '94 Disco 1 auto box has over 590,000km on it.

  5. #5
    lewy is offline Wizard Silver Subscriber
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    realistically its probably\definatly beyond my bush skills,$so is $6000

  6. #6
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    Do you even need that puller?
    You stirred me to watch [ame]https://youtu.be/JGbsgpp2YJQ[/ame] and part 2. It actually makes the inside a bit less scary.
    There is also a 2 hour video of a honda auto rebuild.
    My fear is paying out, doing all the work and *still* not having a working box. I don't have the kind of workspace to cleany tear down and rebuild.
    Does that pack have all the o rings throughout the box?

    Sent from my SM-T530 using AULRO mobile app

  7. #7
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    I asked Ashcrofts about something similar and he said he had a few NEW 24's,,
    I am resigned to my needing one at some stage--
    "How long since you've visited The Good Oil?"

    '93 V8 Rossi
    '97 to '07. sold.
    '01 V8 D2
    '06 to 10. written off.
    '03 4.6 V8 HSE D2a with Tornado ECM
    '10 to '21
    '16.5 RRS SDV8
    '21 to Infinity and Beyond!


    1988 Isuzu Bus. V10 15L NA Diesel
    Home is where you park it..

    [IMG][/IMG]

  8. #8
    lewy is offline Wizard Silver Subscriber
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    maybe we should do a group buy

  9. #9
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    Nope it is not a puller, it is for compressing the springs on the clutch pack you could make one up but as time is a factor for me and it was a good price, on one of the BMW sites there is a video of some one doing the ZF4HP22EH valve bank and forward clutch pack.
    disco seriesII mods so far:-bullbar,hyd winch,
    detriot locker,lsd front,C.D.L kit,chipped and bigger intercooler,2" lift,rock sliders, lsd in transfer case, modified auto trans.

    In the event of nuclear war,Disregard this message

  10. #10
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    Nylon balls are used in the valve bank and these are prone to wear causing leakage
    disco seriesII mods so far:-bullbar,hyd winch,
    detriot locker,lsd front,C.D.L kit,chipped and bigger intercooler,2" lift,rock sliders, lsd in transfer case, modified auto trans.

    In the event of nuclear war,Disregard this message

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