2001 LAND ROVER FREELANDER gearbox

FUEL DELIVERY SYSTEM - PETROL
19-2-24 REPAIRS
Sensor - heated oxygen (H02S) - post
catalyst - LH - KV6 - Non NAS
$% 19.22.71
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 gear selector knob.

+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Gear knob.
3.Release clips securing selector lever trim panel
to centre console and move trim panel aside.
4.Disconnect HO2S multiplug from harness.
5.Release grommet and withdraw HO2S harness
multiplug through grommet aperture.6.Remove HO2S.
Refit
1.Clean HO2S and mating face.
2.Fit HO2S and tighten to 55 Nm (41 lbf.ft) using
tool LRT-19-014.
3.Feed HO2S harness through grommet aperture
and secure grommet.
4.Connect HO2S multiplug.
5.Fit trim panel and gaiter to centre console and
secure clips.
6.Fit gear selector knob.

+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Gear knob.
7.Remove stand(s) and lower vehicle.

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
REPAIRS 30-3-1
MANIF OLDS & EX HAUST SYSTEMS - K SERIES KV6 REPAIRS
Front pipe - Non NAS
$% 30.10.09
Remove
1.Remove gear selector knob.

+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Gear knob.
2.Release clips securing selector lever trim panel
to centre console and move trim panel aside.
3.Release and disconnect post catalyst HO2S
multiplug.
4.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
5.Release grommet and withdraw HO2S harness
multiplug through grommet aperture.6.Remove nut securing exhaust heat shield to
mounting bracket.
7.Remove 2 nuts securing heat shield to IRD
pinion housing.
8.Remove heat shield.
9.Remove 4 nuts securing front pipe flanges to
exhaust manifolds.
10.Release manifold flanges.

MANIFOLDS & EXHAUST SYSTEMS - K SERIES KV6
30-3-2 REPAIRS
11.Remove 3 nuts securing front pipe to
intermediate pipe.
12.Release intermediate pipe from front pipe.
13.Remove gasket.
14.Remove exhaust front pipe.
15.Remove HO2S.Refit
1.Clean HO2S and mating face.
2.If refitting existing HO2S, apply anti-seize
compound to HO2S threads.
3.Fit HO2S and tighten to 55 Nm (41 lbf.ft)using
tool LRT-19-014.
4.Clean exhaust pipe and manifold flanges.
5.Fit exhaust front pipe.
6.Using new gasket, connect intermediate pipe to
front pipe, fit nuts and tighten to 50 Nm (37
lbf.ft).
7.Position LH exhaust manifold flange to front
pipe, fit and tighten nuts to 50 Nm (37 lbf.ft).
8.Position RH exhaust manifold flange to front
pipe, fit and tighten nuts to 50 Nm (37 lbf.ft).
9.Fit exhaust heatshield and fit nuts finger tight.
10.Tighten nut securing exhaust heatshield to
exhaust mounting bracket to 45 Nm (33 lbf.ft).
11.Tighten nuts securing exhaust heatshield to
pinion housing to 25 Nm (18 lbf.ft).
12.Feed HO2S harness through grommet aperture
and secure grommet.
13.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
14.Connect HO2S multiplug.
15.Fit trim panel and gaiter to centre console and
secure clips.
16.Fit gear selector knob.

+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Gear knob.

INTERMEDIATE REDUCTION DRIVE
ADJUSTMENTS 41-1
INTERMEDIATE RE DUCTION DRIVE ADJUST ME NTS
Intermediate reduction drive (IRD) fluid -
drain & refill - Non NAS
$% 41.25.06
Drain
1.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
2.Place container beneath IRD unit.
WARNING: Observe due care when draining
gearbox fluid as the fluid can be very hot.
3.Clean area around filler/level and drain plugs.
4.Remove filler/drain plugs and discard sealing
washers. Allow fluid to drain.
NOTE: The fluid should be drained with the
transmission at normal operating temperature.
5.Fit new sealing washer and tighten drain plug to
35 Nm (26 lbf.ft).Refill
1.Fill with correct fluid until it just runs from filler/
level hole. Allow sufficient time for fluid to flow
and reach a common level in unit.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
2.Fit new sealing washer and tighten filler/level
plug to 35 Nm (26 lbf.ft).
3.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.

INTERMEDIATE REDUCTION DRIVE
41-2 ADJUSTMENTS
Intermediate reduction drive (IRD)
lubrication system - drain & refill - NAS
$% 41.25.06
Drain
1.Remove underbelly panel

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
2.Place container beneath IRD unit.
WARNING: Observe due care when draining
gearbox fluid as the fluid can be very hot.
3.Clean area around filler/level and drain plugs.
4.Using LRT-41-021 remove filler plug and
discard sealing washer.5.Remove drain plug, discard sealing washer and
allow oil to drain.
NOTE: The fluid should be drained with the
transmission at normal operating temperature.
6.Fit new sealing washer and tighten drain plug to
35 Nm (26 lbf.ft).
Refill
1.Fill with fluid until it just runs from filler/level
hole. Allow sufficient time for fluid to flow and
reach a common level in unit.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
2.Fit new sealing washer and tighten filler/level
plug to 35 Nm (26 lbf.ft).
3.Fit underbelly panel

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
M417853
LRT-41-021
M41 7687

INTERMEDIATE REDUCTION DRIVE
REPAIRS 41-3
REPAIRS
Intermediate reduction drive (IRD) unit -
Td4
$% 41.25.01.99
Remove
1.Disconnect battery earth lead.
2.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.
3.Remove rear beam.

+ FRONT SUSPENSION, REPAIRS,
Rear beam.
4.Remove exhaust front pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- Td4, REPAIRS, Exhaust pipe - front.
5.Drain fluid from IRD.

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

+ MANUAL GEARBOX - GETRAG,
ADJUSTMENTS, Gearbox oil - drain and
refill.

+ AUTOMATIC GEARBOX - JATCO,
ADJUSTMENTS, Gearbox fluid - drain &
refill.
7.Remove 3 bolts securing RH splash shield to
body and remove shield.8.Secure LRT-54-026 to drive shaft inboard joint.
Using a suitable lever, release drive shaft from
IRD.
9.With assistance, pull hub outwards and release
drive shaft from IRD.
10.Remove and discard drive shaft circlip.
11.Reference mark front propeller shaft for
reassembly.
12.Raise one rear wheel for rotation of propeller
shaft to access bolts.

INTERMEDIATE REDUCTION DRIVE
REPAIRS 41-5
21.Remove 2 bolts securing support bracket to
IRD.
22.Remove support bracket.
23.Remove 3 bolts, securing IRD upper support
bracket to cylinder block.
24.Remove 2 bolts securing upper support bracket
to IRD.
25.Remove IRD upper support bracket.
26.Remove 4 bolts securing IRD.
27.With assistance, release IRD from gearbox and
remove.28.Remove and discard 'O' ring from IRD.
M41 7698

INTERMEDIATE REDUCTION DRIVE
41-6 REPAIRS
Refit
1.Clean mating faces of IRD and gearbox.
2.Lubricate and fit new 'O' ring
3.With assistance, fit IRD.
4.Fit bolts securing IRD to gearbox and tighten
sufficiently only to pull mating faces of IRD and
gearbox together at this stage.
5.Fit IRD support brackets, tighten sufficiently to
pull mating faces together.
6.Final tighten bolts securing IRD to gearbox to
90 Nm (66 lbf.ft).
7.Final tighten bolts securing IRD support
brackets in the following sequence:
lM8 bolts securing support brackets to IRD
37 Nm (22 lbf.ft)
lM10 bolts securing support brackets to IRD
50 Nm (22 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).
8.Position lower engine steady, 'TOP' mark
uppermost. Fit bolt but do not tighten at this
stage.
9.Connect coolant hoses and secure with clips.
10.Connect breather hose to IRD housing.
11.Clean propeller shaft flange and mating face.
12.Fit propeller shaft to IRD flange and align
marks. Tighten nuts and bolts to 40 Nm (30
lbf.ft).
13.Inspect drive shaft oil seal, renew if worn or
damaged.14.Clean drive shaft and flange splines.
15.Fit new circlip to drive shaft.
16.With assistance, pull hub outwards, align drive
shaft and fit to IRD taking care not to damage
oil seal.
17.Fit splash shield and secure with bolts.
18.Fit exhaust front pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- Td4, REPAIRS, Exhaust pipe - front.
19.Fit rear beam.

+ FRONT SUSPENSION, REPAIRS,
Rear beam.
20.Final tighten bolt securing lower engine steady
to IRD support bracket to 100 Nm (74 lbf.ft).
21.Remove stand(s) and lower vehicle.
22.Fill IRD to correct level with fluid.

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

+ MANUAL GEARBOX - GETRAG,
ADJUSTMENTS, Gearbox oil - drain and
refill.

+ AUTOMATIC GEARBOX - JATCO,
ADJUSTMENTS, Gearbox fluid - drain &
refill.
24.Connect battery earth lead.
25.Refill cooling system.

+ COOLING SYSTEM - Td4,
ADJUSTMENTS, Coolant - drain and refill.