2001 LAND ROVER FREELANDER Workshop Manual

INTERMEDIATE REDUCTION DRIVE
41-30 REPAIRS
Seal - pinion gear housing - KV6 - 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.Remove front exhaust pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Front pipe - NAS.
4.Drain fluid from IRD.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) lubrication system -
drain & refill - NAS.
5.Raise one rear wheel for rotation of propeller
shaft to access bolts.
6.Reference mark front propeller shaft for
reassembly.
7.Remove 6 nuts and bolts securing propeller
shaft to IRD drive flange.
8.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.
9.Remove 2 nuts from pinion housing securing
front exhaust pipe bracket, remove bracket.
10.Remove nut securing heat shield to IRD unit,
remove shield.11.Remove 2 remaining nuts securing pinion
housing.
12.Remove pinion housing.
13.Remove and discard 'O' ring.
14.Remove and retain spacing washer.

INTERMEDIATE REDUCTION DRIVE
REPAIRS 41-31
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 bracket and heat shield, secure with
nuts and tighten to 10 Nm (7 lbf.ft).
7.Fit nut securing heat shield to IRD and tighten
to 45 Nm (33 lbf.ft).
8.Fit remaining nuts securing pinion housing and
tighten all nuts to 25 Nm.
9.Ensure mating face of propeller shaft and IRD
drive flange are clean.
10.Fit propeller shaft to IRD flange and align
marks. Tighten nuts and bolts to 42 Nm (31
lbf.ft).
11.Fit front exhaust pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Front pipe - NAS.
12.Lower axle and remove jack.
13.Fill IRD to correct level with fluid.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) lubrication system -
drain & refill - NAS.
14.Fit underbelly panel.

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

AUTOMATIC GEARBOX - JATCO
ADJUSTMENTS 44-1
AUTOMATIC GE ARBOX - JATCO ADJUST ME NTS
Inhibitor switch - adjust
$% 44.15.18
Adjust
1.Set gear selector lever to 'N' position.
2.Loosen 2 bolts securing inhibitor switch to
gearbox casing.
3.Fit tool LRT-44-018 to selector lever on
gearbox, rotate inhibitor switch sufficient to
insert tool alignment pin through tool lever into
inhibitor switch.
4.Tighten inhibitor switch bolts to 3 Nm (2.2
lbf.ft)and remove LRT-44-018.
5.Check that the engine will start in 'P' and 'N'
positions and is inhibited when drive positions
are selected.
M44 1645A
LRT-44-018

AUTOMATIC GEARBOX - JATCO
44-2 ADJUSTMENTS
Gearbox fluid - drain & refill
$% 44.24.02
Drain
1.Position vehicle on ramp.
WARNING: Observe due care when draining
gearbox fluid as the fluid can be very hot.
2.Apply handbrake and position chocks under
front and rear wheels.
3.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
4.Position container under gearbox.
NOTE: The fluid should be drained with the
transmission at normal operating temperature.
5.Clean area around drain plug.
6.Remove drain plug and discard sealing washer.
7.Allow fluid to drain.
8.Clean drain plug and fit new sealing washer.
9.Fit drain plug and tighten to 45 Nm (33 lbf.ft).Refill
1.Clean area around filler plug.
2.Remove filler plug.
3.Add 3.5 to 4 litres of the correct fluid through
gearbox filler.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
4.Clean and fit filler plug.
5.Check and top-up fluid level.

+ MAINTENANCE, MAINTENANCE,
Automatic Gearbox – JATCO.
6.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
M44 1641
M44 1642

AUTOMATIC GEARBOX - JATCO
ADJUSTMENTS 44-3
Selector cable - adjust
$% 44.30.04
Adjust
1.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
2.Loosen trunnion nut securing inner cable to
selector lever.
3.Move gear change lever into 'P' position.
4.Move selector lever on gearbox fully clockwise
to engage 'P' position.
5.Pull inner cable as far forward as possible, then
release. This will remove any backlash from the
cable.
6.Tighten trunnion nut to 6 Nm (4 lbf.ft).
7.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
8.Move selector lever through its working arc;
from 'P' to '2' and back to 'P', checking that all
gear positions are correctly selected.
9.Check that the engine will start in 'P' and 'N'
positions and is inhibited when drive positions
are selected.
M44 1640

AUTOMATIC GEARBOX - JATCO
REPAIRS 44-5
REPAIRS
Selector housing
$% 44.15.04
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 front console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - front - up to 04MY.
3.Release inner cable from selector lever.
4.Remove 'C' clip securing outer cable to selector
housing.
5.If fitted, release mirror fold ECU and place
aside.
6.Disconnect shift interlock solenoid connector.
7.Disconnect multiplug from sport/manual switch.
8.If fitted, remove bolt and disconnect cable from
key interlock mechanism.9.Remove 6 nuts securing selector housing.
10.Remove selector housing.
11.Remove screw and remove mirror fold ECU
housing.
Refit
1.Position mirror fold ECU housing and secure
with screw.
2.Fit selector housing, fit nuts and tighten to 10
Nm (7.5 lbf.ft).
3.Connect key interlock mechanism inner cable.
Locate outer cable, fit clamp and clamp bolt but
do not tighten clamp bolt at this stage.
4.Connect multiplug to sport/manual switch.
5.Connect shift interlock solenoid connector.
6.Secure inner cable to selector lever.
7.Secure outer cable to selector housing with 'C'
clip.
8.Check key interlock cable adjustment.

+ STEERING, ADJUSTMENTS, Cable
- key interlock - adjust.
9.Fit front console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - front - up to 04MY.
10.Remove stand(s) and lower vehicle.