2001 LAND ROVER FREELANDER Workshop Manual

INTERMEDIATE REDUCTION DRIVE
41-14 REPAIRS
Gasket - end cover - IRD housing - Td4
$% 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 nut securing manifold heat shield to
IRD unit.
4.Remove nut securing heat shield to IRD pinion
housing.
5.Remove 2 bolts securing heat shield and
remove heat shield.
6.Remove lower engine steady.

+ ENGINE - Td4, REPAIRS, Engine
steady - lower.
7.Remove 3 bolts securing IRD support bracket
to sump.8.Remove 2 bolts securing support bracket to
IRD and remove bracket.
9.Remove 3 bolts, securing IRD upper support
bracket to cylinder block.
10.Remove 2 bolts securing upper 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 41-15
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
41-20 REPAIRS
5.Remove primary shaft from main case.
6.Remove 2 seals from primary shaft.
7.Remove 2 seals from main case.
Refit
1.Clean primary gear shaft and intermediate
shaft and differential.
2.Clean seal locations.
3.Fit seal to each end of primary gear shaft with
seal lips facing outwards.
4.Fit primary gear shaft to main case.
5.Fit suitable protection over splines on
intermediate shaft.
6.Carefully fit intermediate shaft to primary shaft.
7.Clean remains of old sealant from mating faces
of end cover and IRD main case.8.Apply a narrow bead of sealant, Part No. STC
4600 to mating face of end cover.
9.Fit end cover to IRD and tighten bolts
progressively to 30 Nm (22 lbf.ft).
10.Fit seal protector, part of LRT-41-015 to IRD
splines.
11.Using plain end of LRT-41-015, fit inner seal
into main case until it contacts shoulder.
CAUTION: The seals are fitted with the main
sealing lips facing away from each other.

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.