2001 LAND ROVER FREELANDER drain bolt

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.

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
REPAIRS 44-27
21.Fit new circlip to LH drive shaft.
22.With assistance, fit LH drive shaft to gearbox,
keep shaft square to prevent damage to oil seal
in gearbox.
23.Fit IRD.

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

+ CHARGING AND STARTING,
REPAIRS, Starter motor - Td4.
25.Fit fluid cooler.

+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Fluid cooler - Td4.
26.Fit intake ducting assembly.

+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Ducting - intake assembly.
27.Connect battery earth lead.
28.Untie and close bonnet.
Fluid pan - reseal
$% 44.24.05
Remove
1.Drain gearbox fluid.

+ AUTOMATIC GEARBOX - JATCO,
ADJUSTMENTS, Gearbox fluid - drain &
refill.
2.Remove fluid cooler.

+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Fluid cooler - KV6.
3.Release multiplugs from clips attached to fluid
pan.
4.Remove 21 bolts securing fluid pan to gearbox.
5.Remove fluid pan.
Refit
1.Clean fluid pan and mating face on gearbox.
2.Apply sealant, Part No. STC 4600to contact
faces of fluid pan and gearbox.
3.Position fluid pan, fit bolts and tighten
progressively to 7 Nm (5 lbf.ft).
4.Secure multiplugs to clips.
5.Fit fluid cooler.

+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Fluid cooler - KV6.
6.Fill gearbox with fluid.

+ AUTOMATIC GEARBOX - JATCO,
ADJUSTMENTS, Gearbox fluid - drain &
refill.

AUTOMATIC GEARBOX - JATCO
44-30 REPAIRS
Fluid cooler - Td4
$% 44.24.10
Remove
1.Disconnect battery earth lead.
2.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
3.Position container to collect coolant spillage.
4.Release 2 clips and disconnect coolant hoses
from fluid cooler.
5.Position container to collect fluid spillage.
6.Disconnect 2 fluid cooler hose unions and
discard 'O' rings.
7.Remove 3 bolts securing fluid cooler bracket.
8.Remove fluid cooler.Refit
1.Clean cooler mounting points.
2.Position fluid cooler to mounting, fit bolts,
tighten 2 bolts to 45 Nm (33 lbf.ft) and
remaining bolt to 25 Nm (18 lbf.ft).
3.Connect coolant hoses and secure with clips.
4.Lubricate new 'O' rings with clean transmission
fluid and fit to fluid cooler hoses.
5.Connect hoses to fluid cooler and tighten
unions to 18 Nm (13 lbf.ft).
6.Top-up gearbox fluid level.

+ MAINTENANCE, MAINTENANCE,
Automatic Gearbox – JATCO.
7.Connect battery earth lead.
8.Refill cooling system.

+ COOLING SYSTEM - Td4,
ADJUSTMENTS, Coolant - drain and refill.
9.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.