2003 Disco II, 121,000 miles

First - I apologize for not using the RAVE CD but I couldn't seem to get it to work on my computer.

I went to do some of the 60K service and was tackling the fluid changes and ran across a few issues/question. I had no problem with the front and rear diffys, fluid looked reasonable and took about the amount specified.

1. When I went to remove the drain plug for the Transfer Case the cross brace was in the way and interfered with the 1/2 inch drive going in. No matter what I did nothing would fit. The cross member was in the way and there was not enough clearance. I needed about 1/4 inch or so more to get the 1/2 inch drive socket or breaker bar in. So I removed the cross member and drained and refilled the Transfer Case then put the cross member back on. My question is whether the interference in normal or is it an indication that there is some problem with the mounts such that the tranny is sagging and that is why there is not enough clearance to get to the plug. I don't remember there being and discussion on this forum about removing the cross member to do this job.

2. The truck had sat for about 1 1/2 hours before I got to the draining of the transmission. I always remove the fill plug first to make sure I can do it so if I can't for some reason I'm not stuck with an empty pan. When I pulled the fill plug the transmission fluid came gushing out - full stream - for some time. I was at a lift draining into a catch barrel so I couldn't measure it but it looked like 4 or 5 quarts total from the fill plug and when I drained the pan. I went ahead and changed the transmission filter and cleaned and put the pan back on. When I went to refill I only got about 2 quarts in before it started coming out the fill hole. I have read several threads and they all say to fill till it come out, then replace plug, shift transmission through the gears and repeat until there is no additional needed. I was just surprised that so much came out and only 2 quarts went in on the first fill. Is that normal. (I am used to a dip stick so this is a little new) Since I don't have dip stick to check I was a little worried about getting the right amount back in.

Since I did not want to damage the tranny I rolled it off the lift and left it at the military auto hobby shop (MCAS Beaufort). With 5 out and only 2 back in can I safely start it and drive the 20 yards back onto the lift to finish the top off or would I be better just crawling under the truck and doing it without driving back on the lift. I don't want to damage the tranny.

Thanks in advance

 

My '03 held 4 quarts after draining. I did not drop the pan. I probably only got about 1/4 quart in after shifting through the gears. That doesn't directly answer your questions, but maybe it will help.

Ps- I wouldn't be too worried about driving it a few feet back to the ramp.

 

When the trans fluid was warm it took up more space, so it looked like more than it actually was.

On a '03 and '04 the transmission is longer by about 4mm so the t-case fill plug will be closer to the cross member than on a '02 for example.

 

I realize the hot fluid expands some. What really surprised me was the full flow from the fill hole, not just a dribble or small stream. It was gushing out the full diameter of the fill hole and with some force. It really surprised me. Is is possible the tranny was overfilled, but with this kind of a system I don't see how you can overfill.

I could only get about 2 quarts in after I put the pan on. Can I reasonably expect to start and drive it up on the ramp without doing som damage?

 

You need to fill it the rest of the way and check up with the engine running, otherwise it all just drains back to the pan and pours out when you pull the plug.

The TC is normal, I used a long wobble extension to get the plug off.

 

Yes, I think you will be fine to start it, run it through the gears and then add more ATF.

These are actually pretty easy to overfill, when you refill it if your hose on your pump is plugging the hole you can pump in 10 qts and not even know it.

 

Spike,

I read our post on filling the tranny.

Fill with engine off till you get fluid coming out the fill hole. - Did that and got about 2 quarts in.

Now on your post it says to start the engine and shift through all gears, leaveng for about 2 seconds each, then check the level and add if necessary. Do you do this check with the engine running and in park or with the engine off and in part? It was not clear to me. If the fluid drains back down with the engine off wouldn't that influence the level check. I know for the DI with a dipstick you check final level with the engine running so it would make sense to do this check on the DII with the engine running.

Thanks in advance

 

Yes check it with the trans in park and then engine running.
Sorry I didnt make that clear.
I would check it again after driving it for a day.

 

Thanks everyone for the help. I was a little paranoid about filling the transmission and getting the right amount in without a dipstick. I was also a little paranoid about the transfer case interference - as an engineer myself I always wonder "who designed this" when I see something like that where just a little further back for the cross member would make this so much easier.

I''ll finish the undercar fluid changes and put in 4 new O2 sensors tomorrow. I have already changed the antifreeze with Peak Longlife OAT. I'll probably get to the plugs/wires, serpentine belt, brake fluid, power steering fluid and other things on the list next week or soon thereafter.

I also rebuilt the front driveshaft with greasable U-joints already so I think I have hit the big failure items first. I know that the 03 has the oil pump issue and I am trying to figure out if the engine has been replaced from Landrover. If not, then I guess its a crap-shoot but with 121,000 miles I would have thought it would have given out by now. It gets 17.8 mpg on the highway which I figure is pretty good for the 4.6L engine. I only paid 5K for the whole thing so I guess if I have to replace the engine I am still about on track since it is in very good shape.

Smokey73

 

Sounds like you are right on track to have a long and happy life with your LR.