2001 LAND ROVER FREELANDER ECU

INTERMEDIATE REDUCTION DRIVE
REPAIRS 41-15
Refit
1.Clean remains of old sealant from mating faces
of end cover and IRD main case.
2.Apply a narrow bead of sealant, Part No. STC
4600to mating face of end cover.
3.Fit end cover to IRD and tighten bolts
progressively to 30 Nm (22 lbf.ft).
4.Fit IRD support bracket and tighten bolts
sufficiently only to pull mating faces together.
5.Final tighten bolts securing IRD support
brackets in the following sequence:
lM10 bolts securing support brackets to IRD
50 Nm (37 lbf.ft)
l3 bolts securing support bracket to cylinder
block 25 Nm (18 lbf.ft)
l3 bolts securing support bracket to sump at
45 Nm (33 lbf.ft).
6.Fit lower engine steady.

+ ENGINE - Td4, REPAIRS, Engine
steady - lower.
7.Fit heat shield.
8.Fit nut securing heat shield to IRD and tighten
to 45 Nm (33 lbf.ft).
9.Fit bolts securing manifold heat shield to IRD
support bracket and tighten to 9 Nm (7 lbf.ft).
10.Fit nut securing heat shield to IRD pinion
housing and tighten to 30 Nm (22 lbf.ft).
11.Fit drive shaft RH seal.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Seal - driveshaft - RH.
12.Fill IRD to correct level with fluid.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
Non NAS.
Gasket - end cover - IRD housing - KV6
$% 41.27.05
Remove
1.Drain fluid from IRD.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
Non NAS.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) lubrication system -
drain & refill - NAS.
2. NAS models: Remove RH catalytic converter.

+ EMISSION CONTROL, REPAIRS,
Catalytic converter - RH - KV6 - NAS.
3.Remove drive shaft RH seal.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Seal - driveshaft - RH.
4. Non NAS models:Remove nut securing
manifold heat shield to IRD unit.
5. Non NAS models:Remove nut securing heat
shield to IRD pinion housing.
6. Non NAS models:Remove 2 bolts securing
heat shield and remove heat shield.
7.Remove engine lower steady.

+ ENGINE - K SERIES KV6, REPAIRS,
Engine steady - lower.

INTERMEDIATE REDUCTION DRIVE
41-16 REPAIRS
8.Remove 3 bolts securing IRD support bracket
to sump.
9.Remove 2 bolts securing IRD support bracket
to engine front mounting plate.
10.Remove 5 bolts securing support bracket to
IRD and remove bracket.11.Remove 8 bolts securing end cover to main
case of IRD.
12.Remove end cover.

INTERMEDIATE REDUCTION DRIVE
REPAIRS 41-17
Refit
1.Clean remains of old sealant from mating faces
of end cover and IRD main case.
2.Apply a narrow bead of sealant, Part No. STC
4600to mating face of end cover.
3.Fit end cover to IRD and tighten bolts
progressively to 30 Nm (22 lbf.ft).
4.Fit IRD support bracket and tighten bolts
sufficiently only to pull mating faces together.
5.Final tighten all bolts in following sequence:
l5 bolts securing support bracket to IRD 50
Nm (37 lbf.ft)
l2 bolts securing support bracket to engine
front mounting bracket 50 Nm (37 lbf.ft)
l3 bolts securing support bracket to sump 88
Nm (65 lbf.ft).
6.Fit engine lower steady.

+ ENGINE - K SERIES KV6, REPAIRS,
Engine steady - lower.7. Non NAS models: Fit heat shield.
8. Non NAS models: Fit nut securing heat shield
to IRD and tighten to 45 Nm (33 lbf.ft).
9. Non NAS models: Fit bolts securing manifold
heat shield to IRD support bracket and tighten
to 9 Nm (7 lbf.ft).
10. Non NAS models: Fit nut securing heat shield
to IRD pinion housing and tighten to 25 Nm (18
lbf.ft).
11.Fit drive shaft RH seal.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Seal - driveshaft - RH.
12.Fill IRD to correct level with fluid.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
Non NAS.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) lubrication system -
drain & refill - NAS.
13. NAS models: Fit RH catalytic converter.

+ EMISSION CONTROL, REPAIRS,
Catalytic converter - RH - KV6 - NAS.

INTERMEDIATE REDUCTION DRIVE
41-18 REPAIRS
Gasket - end cover - IRD housing - K1.8
$% 41.27.05
Remove
1.Drain fluid from IRD.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
Non NAS.
2.Remove drive shaft RH seal.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Seal - driveshaft - RH.
3.Remove bolt securing engine lower steady to
beam.
4.Remove bolt securing engine lower steady to
bracket on sump.
5.Remove engine lower steady.
6.Remove 3 bolts securing lower engine steady
bracket to sump and remove bracket.7.Remove upper bolt securing IRD support
bracket to cylinder block.
8.Remove 5 bolts securing support bracket to
IRD.
9.Remove 3 bolts securing IRD support bracket
to sump and remove bracket.
10.Remove 8 bolts securing end cover to main
case of IRD.
11.Remove end cover.
12.Remove bolt securing engine lower steady to
bracket on sump.
M12 7144
M12 7165
M12 7166

INTERMEDIATE REDUCTION DRIVE
REPAIRS 41-19
Refit
1.Clean remains of old sealant from mating faces
of end cover and IRD main case.
2.Apply a narrow bead of sealant, Part No. STC
4600to mating face of end cover.
3.Fit end cover to IRD and tighten bolts
progressively to 30 Nm (22 lbf.ft).
4.Fit IRD support bracket and tighten bolts
sufficiently only to pull mating faces together.
5.Final tighten bolts securing IRD support bracket
in following sequence:
l5 bolts securing IRD support bracket to IRD
50 Nm (37 lbf.ft),
l1 bolt securing support bracket to cylinder
block 45 Nm (33 lbf.ft),
l3 bolts securing support bracket to sump 88
Nm (65 lbf.ft).
6.Position engine lower steady bracket to sump,
fit and tighten bolts to 100 Nm (74 lbf.ft).
7.Fit engine lower steady, fit bolts and tighten to
80 Nm (59 lbf.ft).
8.
9.Fit drive shaft RH seal.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Seal - driveshaft - RH.
10.Fill IRD to correct level with fluid.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
Non NAS.
Seals - primary gear shaft
$% 41.29.02
Remove
1.Remove IRD.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Intermediate reduction
drive (IRD) unit - K1.8.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Intermediate reduction
drive (IRD) unit - Td4.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Intermediate reduction
drive (IRD) unit - KV6.
2.Remove 8 bolts securing end cover to main
case of IRD.
3.Remove end cover.
4.Remove intermediate shaft and differential
from primary shaft.

INTERMEDIATE REDUCTION DRIVE
REPAIRS 41-21
12.Using flanged end of LRT-41-015 fit outer seal
to depth dictated by tool flange.
CAUTION: Use end protector of LRT-41-015
to avoid damage to the working surfaces of
the tool.
13.Remove oil seal protector.
14.Fit IRD.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Intermediate reduction
drive (IRD) unit - K1.8.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Intermediate reduction
drive (IRD) unit - Td4.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Intermediate reduction
drive (IRD) unit - KV6.
Seal - pinion gear
$% 41.29.04
Remove
1.Remove pinion housing.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Seal - pinion gear
housing - Td4.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Seal - pinion gear
housing - K1.8.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Seal - pinion gear
housing - KV6 - Non NAS.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Seal - pinion gear
housing - KV6 - NAS.
CAUTION: Before dismantling the pinion
housing, measure the turning torque on
existing bearings.
2.Attach pinion housing to suitable mounting
plate and secure mounting plate in vice.
3.Check pinion torque to turn figure.
4.Reference mark pinion flange and pinion shaft
for assembly purposes.
5.Restrain pinion flange using LRT-51-003.
6.Remove and discard nut.
7.Position pinion housing onto press, fit suitable
adaptor on end of pinion shaft, press pinion
shaft from drive flange and housing.
8.Remove and discard collapsible spacer.
9.Using a suitable lever, remove pinion oil seal.
CAUTION: Take care to avoid damage to oil
seal recess.
10.Remove pinion bearing inner race.

INTERMEDIATE REDUCTION DRIVE
41-22 REPAIRS
Refit
1.Clean pinion shaft, drive flange and housing.
2.Clean oil seal recess.
3.Lubricate and fit bearing to pinion housing.
4.Lubricate new seal.
5.Using a suitable adapter, press seal into
housing.
CAUTION: Oil seal must be flush with end of
pinion housing.
6.Assemble pinion to housing using new
collapsible spacer.
7.Lightly lubricate drive flange splines with
Molybdenum Disulphide grease.
8.Align pinion to drive flange reference marks
and press flange onto pinion shaft until a 2 mm
clearance exists in bearings.
9.Fit pinion assembly to mounting plate and
secure in vice.
10.Fit new pinion nut, hold pinion drive flange
using LRT-51-003 and tighten pinion nut to 150
Nm (111 lbf.ft).
11.Check pinion torque to turn figure.
NOTE: Figure for new bearings is 180 to 200
Ncm.
If original bearing figure is above 20 to 30 Ncm
and below new bearing figure, set to figure
recorded.
If original bearing is below 20 Ncm set to 20 to
30 Ncm.12.If turning torque is too low, carefully tighten nut
and recheck reading. If turning torque is too
high, pinion assembly will have to be
dismantled and a new collapsible spacer fitted.
Reassemble using new nut and recheck turning
torque.
13.Check drive flange run-out using a Dial Test
Indicator (DTI).
CAUTION: The drive flange run-out should
not exceed 0.05 mm.
14.Remove pinion housing from vice and
mounting plate.
15.Fit pinion housing.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Seal - pinion gear
housing - Td4.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Seal - pinion gear
housing - K1.8.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Seal - pinion gear
housing - KV6 - Non NAS.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Seal - pinion gear
housing - KV6 - NAS.

INTERMEDIATE REDUCTION DRIVE
REPAIRS 41-25
Seal - driveshaft - RH
$% 41.29.09
Remove
1.Remove RH drive shaft.

+ DRIVESHAFTS, REPAIRS, Shaft
with both joints - RH.
2.Carefully remove and discard oil seal, take care
not to damage oil seal recess.
Refit
1.Clean oil seal recess.
2.Locate seal on tool LRT-37-031 and replacer
LRT-37-027 with sealing lip facing towards
housing.
3.Carefully drift oil seal into housing until fully
seated in recess.
4.Fit RH drive shaft.

+ DRIVESHAFTS, REPAIRS, Shaft
with both joints - RH.
Seal - pinion gear housing - Td4
$% 41.29.11
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
3.Drain fluid from IRD.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
Non NAS.
4.Raise one rear wheel for rotation of propeller
shaft to access bolts.
5.Reference mark front propeller shaft for
reassembly.
6.Remove 6 nuts and bolts securing propeller
shaft to IRD drive flange.
7.Release propeller shaft from IRD drive flange
and tie shaft aside.
CAUTION: Care must be taken to support
the Tripode joint when removed from the
IRD unit. To avoid damage to gaiter or steel
can, the joint should not be allowed to fully
extend or be dropped.