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Rover 800 820 Auto Gear Box Replacement.


Rover 800 820 Auto Gear Box Replacement.
1999 Rover 800 820 with Faulty Automatic Gear Box.

Car: 1999 Rover 800 820 Auto Fastback

Colour: Charcoal Grey / Black

This car had started getting a bit of slippage in first gear, but it only happened after about half an hour when the gear box got hot. We had tried changing the auto gear box oil (for the recommended Hondamatic ATF Z1) & oil filter to see if that would make it any better. This did improve the gear lever selection a little and the gear changes also became a much smoother and quieter, but the problem of the car slipping in first gear once the auto gear box got hot continued!

As the car/gearbox was now 10 years old, and we believe that it had had a gear box oil change some years earlier wrongly having 'Dexron II' oil used, any permanent damage must of already been done. It seemed like it could be a sticking valve, as it was always okay if you kept the selector in 'drive' and only became a problem if you moved the gear lever out of and then back into 'drive' (Reverse was still fine).

Also it would drive as normal again if you stopped for a while to let it all cool back down. In the end, thanks to another Rover 800 Auto owner, we were able to locate a brand new Rover Factory Remanufactured auto gear box from an X-Part dealer very cheaply for about a third of the price that it should of cost normally & so we decided that it would be cheaper to replace than fix the old one.

We were very fortunate to be able to get the gear box, as it was only 1 that they were clearing from stock.

It seemed like it was going to be a daunting task, but with all the tools, jacks and axle stands at the ready, we were more than willing to give it ago.

As we started we did think about how the job might be a bit easier if only we had a large jack to lower the gear box down on to. So, my brother disappeared for a bit, and managed to come back later with a borrowed one. This made the whole job far easier. Especially when it came to lifting the new gear box up into place.

Fitting the new gear box turned out to be far easier than we ever expected! (We did think it might take a few days/weeks!).

The best bit though was taking the car out for a drive. It was amazing just how smooth all the gear changes were, and how much easier it was to select the gears. The car now drives like new. Amazing considering what might of happened to the car had we not been able source a gearbox so cheaply. (We would of probably kept it going somehow though).

This Rover 800 has always felt good to drive it, but now it has been improved on. Why would we ever want to change it!



Rover 800 820 Auto Gear Box Replacement.
1999 Rover 800 820 With Faulty Auto Gear Box Oil. Body Jacked up & Supported on Axle Stands.

Rover 800 820 Auto Gear Box Replacement.
Battery, ECU, & Air Intake Box Removed. Gear Selector Cable & Gear Box Oil Cooler Pipes Disconnected.

Rover 800 820 Auto Gear Box Replacement.
Underbody Plastic Skid Panel Rotated out of Way (It was Not Removed Fully as 1 Bolt was bad!). Gearbox Drained.

Rover 800 820 Auto Gear Box Replacement.
Passenger Side Wheel Removed. Suspension, Brakes, Driveshaft and Wheel Hub all Disconnected.

Rover 800 820 Auto Gear Box Replacement.
Anti-Roll Bar and Plastic Liner and Drive Shaft Removed. Engine Supported on Jack. Passenger Wheel Removed.

Rover 800 820 Auto Gear Box Replacement.
Starter Motor (& Solenoid) was Removed Revealing Flywheel. Passenger Side Liner Removed. Passenger Side Driveshaft Pulled out of Gearbox.

Rover 800 820 Auto Gear Box Replacement.
The Long Support Member has been Removed. The Auto Gear Box Dipstick Has Been Removed and Plastic Bag used to Prevent Any Spills.

Rover 800 820 Auto Gear Box Replacement.
Lower Bracket Now Removed.

Rover 800 820 Auto Gear Box Replacement.
The Engine was Turned at the Crank Shaft to Rotate the Flywheel to Remove 3 Bolts in Flywheel.

Rover 800 820 Auto Gear Box Replacement.
The Gear Box was Now Supported on a Large Trolley Jack. The Trolley Jack would be Ideal to Lower out The Gearbox.

Rover 800 820 Auto Gear Box Replacement.
The Front Engine/Gearbox Mount Was Undone.

Rover 800 820 Auto Gear Box Replacement.
The Front Engine/Gearbox Mount Was Removed.

Rover 800 820 Auto Gear Box Replacement.
The Rear Gearbox Mount Was Removed.

Rover 800 820 Auto Gear Box Replacement.
The Bracket Between Gear Box to Engine Mount was also Removed.
BEWARE: There is another Gear Box Mount to Undue. This is located on top of the Gear Box Underneath the ABS unit!
This one is not Mentioned in the Haynes manual!
If you don't undue it, then the Rubber will Just Rip off the Metal Part.
Like ours did!

Rover 800 820 Auto Gear Box Replacement.
Then Undue the Remaining Bolts Securing the Transmission to the Engine and Lower the Gear Box Out.

Rover 800 820 Auto Gear Box Replacement.
The Flywheel can be Inspected at this Point. The Condition of this One is Good, with all Teeth Present and with Very Little Visible Wear.

Rover 800 820 Auto Gear Box Replacement.
The Original Rover Gear Box and Torque Converter Removed.

Rover 800 820 Auto Gear Box Replacement.
The New Rover Factory Remanufactured Gear Box and Torque Converter.

Rover 800 820 Auto Gear Box Replacement.
The New Rover 800 820 Auto Gear Box and Torque Converter.

Rover 800 820 Auto Gear Box Replacement.
The New Rover 800 Auto Gear Box Lined up on Trolley Jack Ready for Fitting.

Rover 800 820 Auto Gear Box Replacement.
At this Point we had Glued the Rubber Engine Mount Back on. (It Later Failed and was Replaced With a Brand New One from X-Part).

Rover 800 820 Auto Gear Box Replacement.
Lifting the Gear Box up on the Large Trolley Jack was Easy.

Rover 800 820 Auto Gear Box Replacement.
The First Few Bolts Were Put Back in Securing the Transmission to the Engine.

Rover 800 820 Auto Gear Box Replacement.
The Front Engine/Gearbox Mount was Connected.

Rover 800 820 Auto Gear Box Replacement.
The Rear Engine/Gearbox Mount and Brackets were Connected. Also the One under the ABS Unit was Tightened Up.

Rover 800 820 Auto Gear Box Replacement.
The Gear Box was Drained of its Factory Oil. This Temporary Oil is put in the gear boxes to Prolong the shelf life and Protect the Gear Boxes. You Have to Remove the Oil Anyway, to Reconnect the Dipstick. So drain it off, replace the bolt, and put new stuff in.

Rover 800 820 Auto Gear Box Replacement.
Hondamatic ATF-Z1 AT Fluid was then added to the Gear Box. See (the previous oil change) Rover 800 820 Auto Gear Box Oil and Filter Change for more info.

Rover 800 820 Auto Gear Box Replacement.
All other Bits were Refitted and by Now the Car had Been Cleaned in a Few Places that had Never Been Cleaned Before. The Whole Removal & Fitting Process was Done in a Day. Although as it was Going Dark this Last photo was taken the Following Morning.




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