2001 LAND ROVER FREELANDER ird

AUTOMATIC GEARBOX - JATCO
REPAIRS 44-13
9.Remove bolt securing engine lower steady to
IRD support bracket.
10.Remove lower engine steady noting that 'TOP'
mark on engine steady faces uppermost.
11.Remove 3 bolts securing IRD support bracket
to sump.
12.Remove 2 bolts securing IRD support bracket
to engine front mounting plate.13.Remove 5 bolts securing support bracket to
IRD.
14.Remove support bracket.
15.Remove 4 bolts securing IRD.
16.With assistance, release IRD from gearbox and
remove.
17.Remove and discard 'O' ring from IRD.
M41 7698

AUTOMATIC GEARBOX - JATCO
44-14 REPAIRS
18.Remove 2 bolts securing torque converter
access plate.
19.Remove access plate.
20.Mark drive plate to torque converter, for refit
purposes.
21.Remove 4 bolts securing drive plate to
converter.
22.Remove bolt securing IRD cooling hose
retainer. Remove retainer.23.Remove bolts securing LRT-44-026 lifting
bracket to gearbox and remove bracket.
24.Remove 3 bolts securing starter motor to
gearbox noting that the LH bolt also secures
the mounting bracket for the CKP sensor
multiplug.
25.Remove starter motor.
M44 1661
M44 1649

AUTOMATIC GEARBOX - JATCO
44-16 REPAIRS
35.Remove 2 top bolts securing gearbox to
engine.
36.Release gearbox from 2 dowels.
37.Remove gearbox assembly.
38.Fit converter retaining plate and secure with
bolts.Refit
1.Remove torque converter retaining plate.
2.Ensure converter is fully located in oil pump
drive by checking depth 'A' as illustrated. Depth
A = 4 mm.
3.Clean gearbox to engine mating faces, dowels
and dowel holes.
4.Fit gearbox assembly.
5.Fit bolts securing gearbox and tighten to 85 Nm
(63 lbf.ft).
6.Disconnect lifting equipment.
7.Clean CKP sensor and mating face.
8.Fit CKP sensor, fit bolt and tighten to 9 Nm (7
lbf.ft).
9.Position fluid cooler, tighten M12 bolts to 85 Nm
(63 lbf.ft) and M8 bolt to 25 Nm (18 lbf.ft).
10.Connect hoses to fluid cooler.
11.Clean fluid cooler unions.
12.Lubricate new 'O' rings with clean transmission
fluid and fit 'O' rings to fluid cooler hoses.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
13.Connect fluid cooler hoses to gearbox and
tighten unions to 18 Nm (13 lbf.ft).
14.Clean starter motor mating faces.
15.Position starter motor to gearbox, align CKP
sensor multiplug bracket, fit and tighten bolts to
45 Nm (33 lbf.ft).
16.Using gearbox bracket bolts, secure LRT-44-
026 lifting bracket to gearbox.
17.Position IRD cooling hose retainer, fit bolt and
tighten to 25 Nm (18 lbf.ft).
18.Align marks on drive plate to torque converter.
19.Fit bolts securing drive plate to torque converter
and tighten bolts to 45 Nm (33 lbf.ft).
20.Clean torque converter access plate.
M44 1689
A
M44 1668

AUTOMATIC GEARBOX - JATCO
REPAIRS 44-17
21.Position access plate, fit bolts and tighten to 9
Nm (7 lbf.ft).
22.Clean mating faces of IRD and gearbox.
23.Lubricate and fit new 'O' ring.
24.With assistance, fit IRD.
25.Fit bolts securing IRD to gearbox and tighten
sufficiently only to pull mating faces of IRD and
gearbox together at this stage.
26.Fit IRD support bracket and tighten bolts
sufficiently only to pull mating faces together.
27.Final tighten bolts securing IRD to gearbox to
80 Nm (59 lbf.ft).
28.Final tighten bolts securing IRD support
bracket in following sequence:5 bolts securing
support bracket to IRD 50 Nm (37 lbf.ft), 2 bolts
securing support bracket to engine front
mounting bracket 50 Nm (37 lbf.ft), 3 bolts
securing support bracket to sump 45 Nm (33
lbf.ft).
29.Position lower engine steady, 'TOP' mark
uppermost. Fit bolt but do not tighten at this
stage.
30.Connect coolant hoses and secure with clips.
31.Connect breather hose to IRD housing.
32.Fit manifold heat shield and fit nut securing
heat shield to pinion housing finger tight.
33.Fit bolts securing manifold heat shield to IRD
support bracket and tighten to 9 Nm (7 lbf.ft).
34.Fit nut securing heat shield to IRD and tighten
to 45 Nm (33 lbf.ft).
35.Final tighten nut securing manifold heat shield
to IRD pinion housing to 25 Nm (18 lbf.ft).
36.Clean exhaust manifold and mating face on
cylinder head.
37.Fit exhaust manifold gasket.
38.Position exhaust manifold, fit nuts and
progressively tighten, from centre outwards to
45 Nm (33 lbf.ft).
39.Connect HO2S multiplug and secure to support
bracket.
Gearbox - KV6
$% 44.20.02.99
Remove
1.Tie bonnet back in upright position.
2.Disconnect battery earth lead.
3.Remove engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
4.Remove IRD.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Intermediate reduction
drive (IRD) unit - KV6.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Intermediate reduction
drive (IRD) unit - KV6.
5.Loosen selector cable trunnion nut.
6.Release clip securing selector cable to gearbox
bracket, remove selector cable and collect
trunnion from selector lever.
7.Remove 3 screws securing LH splash shield
and remove shield.

AUTOMATIC GEARBOX - JATCO
44-18 REPAIRS
8.Secure LRT-54-026 to drive shaft inboard joint.
Using a suitable lever, release inboard joint
from gearbox.
9.With assistance pull hub outwards and release
drive shaft from gearbox.
CAUTION: Care must be taken not to
damage oil seal when removing drive shaft
from gearbox
10.Remove and discard circlip from drive shaft.11.Remove 2 bolts securing torque converter
access plate.
12.Remove access plate.
13.Mark drive plate to torque converter, for refit
purposes.
14.Remove 4 bolts securing drive plate to
converter.
15.Remove bolt securing IRD cooling hose
retainer. Remove retainer.
M44 1661
M44 1649

AUTOMATIC GEARBOX - JATCO
REPAIRS 44-23
23.Fit CKP sensor, fit bolt and tighten to 9 Nm (7
lbf.ft).
24.Position fluid cooler, tighten M12 bolts to 85 Nm
(63 lbf.ft) and M8 bolt to 25 Nm (18 lbf.ft).
25.Clean fluid cooler unions.
26.Lubricate new 'O' rings with clean transmission
fluid and fit 'O' rings to fluid cooler hoses.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
27.Connect fluid cooler hoses to gearbox and
tighten unions to 18 Nm (13 lbf.ft).
28.Clean exhaust manifold and mating face on
cylinder head.
29.Fit exhaust manifold gasket.
30.Position exhaust manifold, fit nuts and
progressively tighten, from centre outwards to
45 Nm (33 lbf.ft).
31.Connect HO2S multiplug and secure to support
bracket.
32.Position IRD cooling hose retainer, fit bolt and
tighten to 25 Nm (18 lbf.ft).
33.Align marks on drive plate to torque converter.
34.Fit bolts securing drive plate to torque converter
and tighten bolts to 45 Nm (33 lbf.ft).
35.Clean torque converter access plate.
36.Position access plate, fit bolts and tighten to 9
Nm (7 lbf.ft).
37.Clean end of drive shaft and mating splines in
gearbox.
38.Fit new circlip to LH drive shaft.
39.With assistance pull hub outwards, align drive
shaft and fit to gearbox, taking care not to
damage drive shaft oil seal.
CAUTION: Pull the drive shaft to ensure the
circlip is fully engaged and retains the shaft.
40.Fit splash shield and secure with bolts.
41.Position trunnion to selector lever, locate inner
cable through trunnion, do not tighten nut at this
stage.
42.Position selector cable to gearbox bracket and
secure with clip.
43.Adjust selector cable.

+ AUTOMATIC GEARBOX - JATCO,
ADJUSTMENTS, Selector cable - adjust.
44.Fit IRD.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Intermediate reduction
drive (IRD) unit - KV6.
45.Connect battery earth lead.
46.Fit engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
47.Untie and close bonnet.
Gearbox - Td4
$% 44.20.02.99
Remove
1.Disconnect battery earth lead.
2.Tie bonnet back in upright position.
3.Remove intake ducting assembly.

+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Ducting - intake assembly.
4.Remove fluid cooler.

+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Fluid cooler - Td4.
5.Remove starter motor.

+ CHARGING AND STARTING,
REPAIRS, Starter motor - Td4.
6.Remove IRD.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Intermediate reduction
drive (IRD) unit - Td4.
7.Secure LRT-54-026 to drive shaft inboard joint.
Using a suitable lever, release inboard joint
from gearbox.
8.With assistance, pull hub outwards and remove
LH drive shaft from gearbox.
CAUTION: Pull the drive shaft horizontally
to avoid damaging the differential oil seal.

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.

DRIVESHAFTS
REPAIRS 47-9
Gaiter - inner joint - rear
$% 47.11.16
Remove
1.Disconnect battery earth lead.
2.Raise rear 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 road wheel.
4.Remove outer gaiter.

+ DRIVESHAFTS, REPAIRS, Gaiter -
outer - rear.
5.Release both gaiter clips and discard.
6.Slide gaiter from shaft.
Refit
1.Clean drive shaft and gaiter.
2.Apply grease from the sachet to the joint.
3.Fit new gaiter to shaft.
4.Apply grease from the sachet to the joint.
5.Position gaiter to joint and use a 'Band-it
thriftool' LRT-99-019 to secure the 2 new clips.
6.Fit outer gaiter.

+ DRIVESHAFTS, REPAIRS, Gaiter -
outer - rear.
7.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
8.Remove stands and lower vehicle.
9.Connect battery earth lead.
Propeller shaft assembly
$% 47.15.01
Remove
1.Raise vehicle on a 4 post ramp.
2.Raise one wheel on each axle for rotation of
propeller shaft as necessary to access fixings.
CAUTION: When working on the propeller
shafts:
lAlways remove the propeller shafts and
viscous coupling as an assembly.
Dismantling the individual units on the
vehicle may cause damage to the
components.
lNever unbolt the viscous coupling
support bearings from the body without
first detaching the propeller shafts at the
differential and IRD. The weight of the
centre section will pull the CV joint apart,
causing irreparable damage.
lNever allow the CV joint to be
manipulated to an acute angle. This will
cause the internal roller bearings to
break up, leading to excessive backlash
and CV joint failure.
3.Reference mark the position of propeller shaft
flanges to IRD and rear axle flanges to aid
reassembly.
4.Remove 6 nuts, bolts and link washers
securing CV joint to IRD flange.