2001 LAND ROVER FREELANDER Workshop Manual

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 41-23
Seal - driveshaft - LH - Td4 & KV6 models
$% 41.29.08
Remove
1.Remove LH drive shaft.

+ DRIVESHAFTS, REPAIRS, Shaft
with both joints - LH.
2.Carefully remove and discard oil seal, take care
not to damage oil seal recess.
Refit
1.Clean oil seal recess.
CAUTION: Oil seal is waxed on outer
diameter and must not be lubricated before
fitting.
2. Models with manual gearbox:Using LRT-54-
025 and LRT-99-003, fit new oil seal.
3. Models with automatic gearbox: Using LRT-
44-027, fit new oil seal.4.Fit LH drive shaft.

+ DRIVESHAFTS, REPAIRS, Shaft
with both joints - LH.
5.Top-up gearbox fluid level.

+ MAINTENANCE, MAINTENANCE,
Automatic Gearbox – JATCO.

INTERMEDIATE REDUCTION DRIVE
41-24 REPAIRS
Seal - drive shaft - LH - K1.8
$% 41.29.08
Remove
1.Remove LH drive shaft.

+ DRIVESHAFTS, REPAIRS, Shaft
with both joints - LH.
2.Carefully remove oil seal from differential
housing, discard oil seal.
Refit
1.Thoroughly clean oil seal recess in differential
housing, splines and oil seal running surface on
drive shaft.
2.Fit handle LRT-37-027 into seal replacer
adaptor, LRT-37-032.
3.Position new oil seal onto LRT-37-032 with
sealing lip facing towards differential housing.
4.Carefully drift oil seal into housing until fully
seated in recess.5.Fully insert oil seal protector tool, Unipart TRV
100060, into differential oil seal so that oil seal
lip is protected and that the split end of tool is
butted correctly.
6.Fit LH drive shaft.

+ DRIVESHAFTS, REPAIRS, Shaft
with both joints - LH.

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.

INTERMEDIATE REDUCTION DRIVE
41-26 REPAIRS
8.Remove 5 nuts securing pinion housing.
9.Remove pinion housing.
10.Remove and discard 'O' ring.
11.Remove and retain spacing washer.Refit
1.Clean pinion housing and mating face on IRD
casing.
2.Clean spacing washer.
3.Fit spacing washer to IRD.
4.Lubricate new 'O' ring with IRD fluid and fit to
groove in pinion housing.
5.Fit pinion housing.
6.Fit nuts securing pinion housing and tighten to
25 Nm (18 lbf.ft).
7.Ensure mating face of propeller shaft and IRD
drive flange are clean.
8.Fit propeller shaft to IRD flange and align
marks. Tighten nuts and bolts to 40 Nm (30
lbf.ft).
9.Fill IRD to correct level with fluid.
+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
Non NAS.
10.Lower axle and remove jack.
11.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
12.Remove stands and lower vehicle.

INTERMEDIATE REDUCTION DRIVE
REPAIRS 41-27
Seal - pinion gear housing - K1.8
$% 41.29.11
Remove
1.Remove underbelly panel.

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

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
Non NAS.
3.Raise one rear wheel for rotation of propeller
shaft to access bolts.
4.Reference mark front propeller shaft for
reassembly.
5.Remove 6 nuts and bolts securing propeller
shaft to IRD drive flange.
6.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.7.Remove 3 nuts securing mass damper to
pinion housing.
8.Remove mass damper.
9.Remove 2 remaining nuts securing pinion
housing.
10.Remove pinion housing.
11.Remove and discard 'O' ring.
12.Remove and retain spacing washer.
Refit
1.Clean pinion housing and mating face on IRD
casing.
2.Clean spacing washer.
3.Fit spacing washer to IRD.
4.Lubricate new 'O' ring with IRD fluid and fit to
groove in pinion housing.
5.Fit pinion housing.
6.Fit mass damper and fit nuts finger tight.
7.Fit remaining nuts securing pinion housing and
tighten all nuts to 25 Nm (18 lbf.ft).
8.Ensure mating face of propeller shaft and IRD
drive flange are clean.
9.Fit propeller shaft to IRD flange and align
marks. Tighten nuts and bolts to 40 Nm (30
lbf.ft).
10.Fill IRD to correct level with fluid.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
Non NAS.
11.Lower axle and remove jack.
12.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
M12 7142

INTERMEDIATE REDUCTION DRIVE
41-28 REPAIRS
Seal - pinion gear housing - KV6 - Non
NAS
$% 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.8.Remove nut securing exhaust heat shield to
mounting bracket.
9.Remove 2 nuts securing heat shield to IRD
pinion housing.
10.Remove heat shield.
11.Remove nut securing manifold heat shield to
IRD unit.
12.Remove nut securing heat shield to IRD pinion
housing.
13.Remove 2 bolts securing heat shield and
remove heat shield.

INTERMEDIATE REDUCTION DRIVE
REPAIRS 41-29
14.Remove 2 remaining nuts securing pinion
housing.
15.Remove pinion housing.
16.Remove and discard 'O' ring.
17.Remove and retain spacing washer.Refit
1.Clean pinion housing and mating face on IRD
casing.
2.Clean spacing washer.
3.Fit spacing washer to IRD.
4.Lubricate new 'O' ring with IRD fluid and fit to
groove in pinion housing.
5.Fit pinion housing.
6.Fit exhaust heat shield and fit nuts finger tight.
7.Fit manifold heat shield and fit nut securing
heat shield to pinion housing finger tight.
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 remaining nuts securing pinion housing and
tighten all nuts to 25 Nm (18 lbf.ft).
11.Tighten nut securing exhaust heat shield to
exhaust mounting bracket to 45 Nm (33 lbf.ft).
12.Ensure mating face of propeller shaft and IRD
drive flange are clean.
13.Fit propeller shaft to IRD flange and align
marks. Tighten nuts and bolts to 40 Nm (30
lbf.ft).
14.Fill IRD to correct level with fluid.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
Non NAS.
15.Lower axle and remove jack.
16.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
17.Remove stands and lower vehicle.