2001 LAND ROVER FREELANDER gearbox

INTERMEDIATE REDUCTION DRIVE
REPAIRS 41-7
Intermediate reduction drive (IRD) unit -
K1.8
$% 41.25.01.99
Remove
1.Disconnect battery earth lead.
2.Remove rear beam.

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

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES 1.8, REPAIRS, Exhaust pipe -
front.
4.Drain fluid from IRD.

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

+ MANUAL GEARBOX - PG1,
ADJUSTMENTS, Gearbox oil - drain and
refill.
6.Remove 3 bolts securing RH splash shield to
body and remove shield.7.Secure LRT-54-026 to drive shaft inboard joint.
Using a suitable lever, release drive shaft from
IRD.
8.With assistance, pull hub outwards and release
drive shaft from IRD.
CAUTION: Care must be taken not to
damage oil seal when removing drive shaft
from IRD.
9.Remove and discard drive shaft circlip.

INTERMEDIATE REDUCTION DRIVE
REPAIRS 41-9
24.Remove 3 bolts securing IRD support bracket
to sump and remove bracket.
25.Remove 4 bolts securing IRD.
26.With assistance, release IRD from gearbox and
remove.
27.Remove and discard 'O' ring from IRD.
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 bracket and tighten bolts
sufficiently only 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 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 to 45 Nm (33 lbf.ft)
l3 bolts securing support bracket to sump 88
Nm (65 lbf.ft).8.Position engine lower steady bracket to sump,
fit and tighten bolts to 100 Nm (74 lbf.ft).
9.Fit engine lower steady, fit bolt securing steady
to gearbox bracket but do not tighten at this
stage.
10.Connect coolant hoses and secure with clips.
11.Connect breather hose to IRD housing.
12.Fit mass damper to pinion housing, fit nuts and
tighten to 25 Nm (18 lbf.ft).
13.Clean propeller shaft flange and mating face.
14.Fit propeller shaft to IRD flange and align
marks. Tighten nuts and bolts to 40 Nm (30
lbf.ft).
15.Inspect drive shaft oil seal, renew if worn or
damaged.
16.Clean drive shaft and flange splines.
17.Fit new circlip to drive shaft.
18.With assistance, pull hub outwards, align drive
shaft and fit to IRD taking care not to damage
oil seal.
CAUTION: Pull the drive shaft to ensure the
circlip is fully engaged and retains the shaft.
19.Fit splash shield and secure with bolts.
20.Fit exhaust front pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES 1.8, REPAIRS, Exhaust pipe -
front.
21.Fit rear beam.

+ FRONT SUSPENSION, REPAIRS,
Rear beam.
22.Final tighten bolt securing lower engine steady
to sump bracket to 80 Nm (59 lbf.ft).
23.Fill IRD to correct level with fluid.

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

+ MANUAL GEARBOX - PG1,
ADJUSTMENTS, Gearbox oil - drain and
refill.
25.Connect battery earth lead.
26.Refill cooling system.

+ COOLING SYSTEM - K SERIES 1.8,
ADJUSTMENTS, Coolant - refill system.
M12 7167
M41 7698

INTERMEDIATE REDUCTION DRIVE
41-10 REPAIRS
Intermediate reduction drive (IRD) unit -
KV6
$% 41.25.01.99
Remove
1.Disconnect battery earth lead.
2.Remove rear beam.

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

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Front pipe - Non
NAS.
4. NAS models: Remove RH catalytic converter.

+ EMISSION CONTROL, REPAIRS,
Catalytic converter - RH - KV6 - NAS.
5. NAS models:Remove LH exhaust manifold
gasket.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Gasket(s) -
exhaust manifold - LH - NAS.
6.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.
7.Drain gearbox fluid.

+ AUTOMATIC GEARBOX - JATCO,
ADJUSTMENTS, Gearbox fluid - drain &
refill.
8.Remove 3 bolts securing RH splash shield to
body and remove shield.9.Secure LRT-54-026 to drive shaft inboard joint.
Using a suitable lever, release drive shaft from
IRD.
10.With assistance, pull hub outwards and release
drive shaft from IRD.
CAUTION: Care must be taken not to
damage oil seal when removing drive shaft
from IRD.
11.Remove and discard drive shaft circlip.

INTERMEDIATE REDUCTION DRIVE
41-12 REPAIRS
24.Remove 3 bolts securing IRD support bracket
to sump.
25.Remove 2 bolts securing IRD support bracket
to engine front mounting plate.
26.Remove 5 bolts securing support bracket to
IRD.
27.Remove support bracket.28.Remove 4 bolts securing IRD.
29.With assistance, release IRD from gearbox and
remove.
30.Remove and discard 'O' ring from IRD.
M41 7698

INTERMEDIATE REDUCTION DRIVE
REPAIRS 41-13
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 bracket and tighten bolts
sufficiently only 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
bracket 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).
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.Fit manifold heat shield and fit nut securing
heat shield to pinion housing finger tight.
12.Fit bolts securing manifold heat shield to IRD
support bracket and tighten to 9 Nm (7 lbf.ft).
13.Fit nut securing heat shield to IRD and tighten
to 45 Nm (33 lbf.ft).
14.Final tighten nut securing manifold heat shield
to IRD pinion housing to 25 Nm (18 lbf.ft).
15.Clean propeller shaft flange and mating face.
16.Fit propeller shaft to IRD flange and align
marks. Tighten nuts and bolts to 40 Nm (30
lbf.ft).
17.Inspect drive shaft oil seal, renew if worn or
damaged.
18.Clean drive shaft and flange splines.
19.Fit new circlip to drive shaft.
20.With assistance, pull hub outwards, align drive
shaft and fit to IRD taking care not to damage
oil seal.
CAUTION: Pull the drive shaft to ensure the
circlip is fully engaged and retains the shaft.21.Fit splash shield and secure with bolts.
22.Fit exhaust front pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Front pipe - Non
NAS.
23.Fit rear beam.

+ FRONT SUSPENSION, REPAIRS,
Rear beam.
24.Final tighten bolt securing lower engine steady
to IRD support bracket to 100 Nm (74 lbf.ft).
25.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.
26. NAS models: Fit RH catalytic converter.

+ EMISSION CONTROL, REPAIRS,
Catalytic converter - RH - KV6 - NAS.
27. NAS models: Fit LH exhaust manifold gasket.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Gasket(s) -
exhaust manifold - LH - NAS.
28.Fill gearbox with fluid.

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

+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.

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.

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