2006 LAND ROVER FRELANDER 2 brake

Publi s hed: 11-May-2011
Ride and Handling Optimization - Ride and Handling Optimization
Diagnosi s and Tes ti ng
Principles of Operation
For a detail ed descripti on of the Terrain Respons e s ys t em, refer t o t he rel evant Descript ion and Operat ion secti on in theworks hop manual .REFER to: Ri de and Handl ing Opt imi zat ion (204-06 Ri de and Handl ing Opt imizati on, Des cript ion and Operat ion).
Inspection and Verification
CAUTION: Di agnos is by s ubs ti tut ion from a donor vehicle is NO T acceptabl e. Subs ti tut ion of cont rol modules doesnot guarant ee confirmat ion of a faul t, and may als o caus e addit ional fault s i n t he vehi cl e being t est ed and/or t he donorvehi cl e.
1. Verify t he cus t omer concern.1.
2. Vis ually ins pect for obvious s igns of mechani cal or electrical damage.2.
Visual InspectionMechanicalElectrical
* Ti re condit ion, pres sures, et cDriveline, Engine, Transmis s ion, Sus pensi on,component s (correct ins tall ati on, damage, etc)
Fus esHarness es /Connect orsTerrai n res pons e modul eEngi ne Cont rol Module (ECM)Transmis s ion Control Modul e (TCM)Ant i-Lock Brake Sys t em control modul eAct ive On-demand cont rol moduleDynami c s us pensi on cont rol module * Controllerarea network (CAN) ci rcuit s
3. If an obvious cause for an obs erved or report ed concern is found, correct t he caus e (if pos s ible) beforeproceeding t o t he next s t ep.3.
4. If t he caus e is not vis ually evi dent , check for Di agnos ti c Trouble Codes (DTCs) and refer t o t he DTC Index.4.
DTC Index
• NOTE: If the control modul e/t rans mis s ion i s s uspect and the vehicle remai ns under manufacturer warrant y, refer t o t heW arranty Pol icy and Procedures manual (s ect ion B1.2), or determine i f any pri or approval programme is in operat ion, pri ort o the ins tall ati on of a new module/transmis s ion.
• NOTE: Generic scan t ool s may not read the codes li st ed, or may read only fi ve digit codes . Mat ch the five di git s from t hes can tool to the firs t fi ve di git s of the seven digi t code l is ted to ident ify t he faul t (t he las t t wo digi ts gi ve addi ti onalinformat ion read by the manufact urer approved diagnos t ic s ys tem).
• NOTE: W hen performing el ect ri cal volt age or resi s tance tes t s, al ways us e a digit al mult imet er (DMM) accurate to threedeci mal places , and wi th an up-to-date cali brat ion cert ificate. W hen t es ti ng res is t ance, always take t he res i st ance of t heDMM leads int o account.
• NOTE: Check and recti fy bas ic faul ts before beginni ng diagnos t ic rout ines i nvol vi ng pinpoint t es t s.
• NOTE: Ins pect connect ors for s igns of water ingres s , and pins for damage and/or corros ion.
• NOTE: If DTCs are recorded and, aft er performi ng the pi npoi nt tes ts , a fault is not present , an int ermi tt ent concern maybe t he caus e. Always check for loose connect ions and corroded terminals .
For a compl ete lis t of all Di agnos ti c Trouble Codes (DTCs) t hat could be logged on this vehicle, pleas e refer to Sect ion100-00.
REFER to: Di agnos ti c Trouble Code (DTC) Index - DTC: Terrain Res pons e Cont rol Modul e (ATCM) (100-00 GeneralInformat ion, Des cript ion and Operat ion).

Bearing Rumbl e
Bearing rumble s ounds l ike marbl es being t umbled. Thi s condi ti on is us uall y caus ed by a worn/damaged wheel bearing.The lower pit ch is because the wheel bearing turns at onl y about one-t hird of the drives haft s peed. W heel bearing nois eals o may be high-pi tched, s imil ar t o gear noi s e, but wi ll be evident in al l four drivi ng modes.
Symptom Chart
SymptomPossible CauseActionNois e i s at cons t ant t oneover a narrow vehi cl e s peedrange. Us ual ly heard onl ight drive and coas tcondi ti ons
Rear drive axl eFor addi ti onal i nformat ion. GO to Pi npoi nt Tes tA.
Nois e i s t he s ame on driveor coas tRoad nois eW orn or damaged dri ves haftjoi ntDriveshaft cent er beari ngW heel bearing
Normal condit ion (road noi se)Check and ins tal l new components a required.REFER t o:Driveshaft - Vehi cl es W i thout: Di eselPart iculat e Fil ter (DPF) (205-01Driveshaft, Removal and Ins tall ati on),Rear W heel Bearing (204-02 RearSus pens ion, Removal and Inst all at ion),Front W heel Bearing (204-01 FrontSus pens ion, Removal and Inst all at ion).
Nois e i s produced wit h t hevehicle s t ati onary andwhen driving
EngineTrans mi ss ionFor addi ti onal i nformat ion. REFER to:Engine (303-00 Engine Syst em - GeneralInformat ion, Di agnos is and Tes ti ng),Di agnos ti cs (307-01 Aut omati cTrans mi ss ion/Transaxle, Di agnos is andTes ti ng).
Loud clunk in the driveli newhen s hifti ng from revers et o forward
Trans mi ss ion cal ibrat ionTrans mi ss ion MountTrans mi ss ionSus pens ion component sBackl ash in t he dri vel ineEngine i dl e s peed s et t oo highEngine mount
Us i ng the manufact urer approved diagnos t ics ys tem, re-configure t he Transmis s ion ControlModule (TCM) wi th the l ates t avai lablecali brati onIns pect and ins t al l new t ransmis s ion mount sas requi redFor t ransmis s ion diagnos ti cs .REFER t o: Diagnos t ics (307-01 Automat icTrans mi s si on/Trans axl e, Diagnos is andTes ti ng).Ins pect and ins t al l new s uspens ioncomponent s as requi redIns pect and ins t al l new dri vel ine component sas requi redCheck and adjus t the i dle s peed as requi redIns pect and ins t al l new engi ne mounts asrequi red
Cli cki ng, popping, orgri nding nois esInadequate or contami nat edl ubricati on in the front /reardri ve halfshaft cons tant veloci ty(CV) jointAnother component cont act ingt he front/rear dri ve hal fs haftW heel bearings , brakes ors uspens ion component s
Ins pect, cl ean and lubri cat e wit h new greaseas requi redEns ure al l ot her components are clear fromfront /rear drive halfs haftIns pect and ins t al l new components asrequi red
Vibrati on at highways peedsOut of balance wheel (s ) ort ire(s )Driveshaft mis ali gned/out ofbalanceDriveshaft cent er beari ngt ouching body mount ing point
Bal ance and i ns t all new wheel(s ) and ti re(s) asrequi red.REFER t o: W heel and Ti re (204-04 W heel s andTi res , Removal and Ins t allat ion).Check dri ves haft ali gnment . Check drives haftbalance us ing manufact urer approveddi agnos ti c s ys t emCheck dri ves haft ali gnment
Shudder, Vibrat ion DuringAccel erati onPowert rai n/dri vel inemi s al ignmentHi gh cons tant velocit y (CV) jointoperat ing angles caus ed byi ncorrect ride hei ght
Check for powert rai n/dri vel ine mis alignmentand rect ify as requi red. Ins t al l newcomponent s as requi redCheck the ri de hei ght and verify the corrects pri ng rat e. Ins t al l new components asrequi red
Lubricant LeakRear drive axl e breatherDamaged s ealRear drive axl e fi ll er pl ugRear drive axl e cover/acti veon-demand coupl ing joint
Check oil level and correct as neces s aryIns tall new drives haft/pinion seal as required.REFER t o: Act ive On-Demand Coupl ing DrivePi ni on Seal (205-02 Rear Dri veAxle/Different ial , Removal and Ins t al lat ion).Check and ins tal l new fi ll er pl ug as requiredRe-seal leaking joint s as required

Not s ens it ive to brake tes ti ng on a chas si s dynamomet er.
Generati on 4 Acti ve On-Demand Coupli ng - Vehicles from 2009MY
The generati on 4 coupl ing does not have the di fferenti al s peed dri ven pump used on the previ ous generat ion 3coupl ing, but i s fit ted wi th a bigger capacit y electrically operated axial pump and a hi gh pres s ure accumul ator.The proport ional throt t le valve and press ure s ens or on t he generat ion 3 coupli ng is replaced wit h a proport ionalpres s ure reducing val ve.The t orque li mit er pres sure reducing valve on the generat ion 3 coupli ng is replaced by an electroni c cont rol valveand cont rol ling software.
The generati on 4 acti ve on-demand coupli ng gives t he fol lowing improvements over t he previous generati on 3 coupl ing:
Reduced bas e t orque at high different ial s peedsTorque acti vat ion i s now i ndependent of different ial s peedAccurat e t orque l imi ter cont rolEnergy s tored in hi gh pres s ure accumul ator givi ng a low maximum current consumpt ion of t he electric pump andfas t er res pons e.
Control Module - G eneration 3 and 4 Couplings
The cont rol module, at tached to the cas ing of t he act ive on-demand coupling, forms a s ingle unit wit h t he cont rolvalve/axial s ol enoi d. By anal yzi ng informat ion from other vehi cl e modules and s ensors t he cont rol module regul ates t heaxial sol enoi d t o cont rol t he hydraul ic flui d pres s ure s uppl ied t o t he clut ch pl ates. Some of t he modul es and s ens ors thecont rol module communi cat es wit h are li s ted below:
Hardwi red:- Control valve / axi al s olenoid- Electric hydrauli c pump- Oi l press ure and temperat ure sens orHigh speed CAN (cont rol ler area net work):- Engine cont rol module- Anti -l ock brake s ys t em / t racti on cont rol module- Tracti on res ponse swit ch- Y aw rate sens or- Steering wheel rot at ion sens or
The axial sol enoi d cons t ant ly adjust s t he cont rol valve output us ing a Pul se W i dt h Modulat ion (PW M) s i gnal. The flui dpres s ure deli vered t o t he cl utch plat es determines t he amount of t orque t hat is delivered t o t he rear axl e.
The act ive on-demand coupli ng has int egrated oi l press ure and temperature s ens ors to enable the control modul e t oaccurat ely manage t he t orque t ransfer under all environment al and operat ing condit ions . Usi ng thes e s ignals the controlmodule will us e s t rategi es to protect the coupli ng from overheati ng; in extreme cas es to protect t he coupli ng from damaget he coupli ng wil l dis engage i f the t emperat ure of t he hydraul ic flui d exceeds 105°C. The coupl ing wi ll ret urn to normalfuncti onal it y when t he temperat ure fall s below 101°C.
The cont rol module has an int egrated di agnos ti cs sys tem, whi ch cons tant ly moni tors the act ive on-demand couplings ys t em as wel l as it s input and output s ignals . If t he control modul e detects a fault a Diagnost ic Troubl e Code (DTC) i ss tored. The DTC is acces s ed usi ng t he Land Rover approved di agnos t ic s yst em.
Electric Hydraulic Pump
W hen negoti ati ng very low frict ion s urfaces s uch as wet gras s , snow or i ce; i nit ial wheel -s pin can cut i nt o t he s urface andreduce gri p. W it h a re-act ive on-demand coupl ing, almos t 60 degrees of wheel rotat ion woul d occur before torque could bet ransmit ted t hrough t he coupl ing.
On Generat ion 3 coupli ngs , t o count eract thi s Land Rover devel oped a uni que high-pres s ure pre-charge faci li ty whi chenergizes t he hydraul ic circui t as s oon as the engi ne is s t art ed. Es s ent ial ly an el ect ri cal ly operat ed hydraul ic pump wasdesi gned to maintai n a pot ent ial of 500 Nm (369 l b ft ) of t orque pres s ure wi thi n the coupli ng. (This pre-charge t orquecapacit y has been increas ed to 1500Nm (1106 l b ft ) for t he Generat ion 4 coupli ng.)
Vehicles fit ted wi th Terrai n Res pons e als o add furt her benefi ts by varying t he level of pre-charge t o deli ver opti mumt racti on over a range of di fferent t errai n s urfaces . The level of pre-charge is varied dependi ng on t he part icul ar terrainres ponse mode, for exampl e:
Terrai n respons e in 'Speci al Programs Off' mode as common wit h vehi cl es wit hout terrain res pons e, the coupli ng isprogrammed t o transmit 500 Nm 369 lb ft of t orque on Generat ion 3 couplings and 1500 Nm (1106 l b ft) of t orqueon Generat ion 4 couplings t o t he rear axle when the vehicle moves from res t i n a s t raight l ine. Thi s s trategymi ni mi zes t ract ion l os s from a s t andi ng-s tart regardles s of t he terrain. W hen the vehicle accelerat es the pres surein the coupling is decreas ed to improve fuel economy.The abili ty to sens e t he s teeri ng angl e all ows t he coupli ng t o be programmed t o provide no torque trans fer t hrought he coupli ng. This prevent s t he coupli ng locking when t he vehicle i s maneuvring at low s peeds and acute s teeri ngangl es.In 'Grass / Gravel / Snow' mode t he coupl ing i s programmed to maint ai n i ts pre-charge s t at e unt il much highers peeds are obtained. The s ame applies even i f the vehicle is t raveli ng at low speeds and acut e s t eering angles , ast racti on takes precedence over coupli ng lock-up on l ow-fri ct ion s urfaces .
For addit ional informat ion, refer t o: Ride and Handli ng Opti mizat ion (204-06 Ride and Handli ng Opt imi zat ion, Descripti onand Operat ion).
Mechanical Hydraulic Pump - Generation 3 Couplings - Vehicles up to 2009MY
The dri ves haft i s att ached t o t he coupl ing's front clut ch pl ate as s embly (i nput ), with the rear cl ut ch plat e as sembl yconnected t o t he different ial pini on (out put ). A s was h-pl ate wit h 6 hydrauli c rol lers is al so att ached t o t he different ialpinion. W hen there is no s peed difference bet ween the coupling's input and out put, the rol lers do not funct ion.

Stage 1:
Stage 2:
Secure t he parking brake cable.
8.
Support the weight of the vehicle us i ng a jack under the rear hub.
9.
10. CAUTIONS: Nut s and bolt s mus t be t ightened wi th the wei ght of t he
vehicle on the s us pens ion. Do not us e ai r tools to i nst all t he nut. Fail ure t o follow thi s
i ns t ructi on may resul t in damage t o t he component.
Tight en bot h l ower arm nut s and bolt s .
T orque: 175 Nm Tight en the trai li ng arm nut and bol t.
T orque: 270 Nm Tight en the rear hal fs haft nut .
T orque: 330 Nm 30°
St ake t he hub nut.10.
Inst all t he s tabil izer bar l ink.
Refer t o: Rear St abi li zer Bar Link (204-02 Rear Sus pensi on, Removal
and Inst all at ion).
11.
Inst all t he wheel and t ire.
Refer t o: W heel and Ti re (204-04 W heel s and Tires, Removal and
Inst all at ion).
12.
13. CAUTION: Do not fill t he different ial wi th lubri cant up t o
t he fi ll er pl ug. The fil ler plug i s only us ed t o fill t he different ial wi th
l ubricant , and not to act as a level i ndicat or.
Fil l the di fferenti al wi th the correct amount of l ubricant .
Refer t o: Different ial Drai ni ng and Fil ling (205-02 Rear Drive
Axle/Different ial, General Procedures).
13.

Stage 1:
Stage 2:
Secure t he parking brake cable.
8.
Support the weight of the vehicle us i ng a jack under the rear hub.
9.
10. CAUTIONS: Nut s and bolt s mus t be t ightened wi th the wei ght of t he
vehicle on the s us pens ion. Do not us e ai r tools to i nst all t he nut. Fail ure t o follow thi s
i ns t ructi on may resul t in damage t o t he component.
Tight en bot h l ower arm nut s and bolt s .
T orque: 175 Nm Tight en the trai li ng arm nut and bol t.
T orque: 270 Nm Tight en the rear hal fs haft nut .
T orque: 330 Nm 30°
St ake t he hub nut.10.
Inst all t he s tabil izer bar l ink.
Refer t o: Rear St abi li zer Bar Link (204-02 Rear Sus pensi on, Removal
and Inst all at ion).
11.
Inst all t he wheel and t ire.
Refer t o: W heel and Ti re (204-04 W heel s and Tires, Removal and
Inst all at ion).
12.
13. CAUTION: Do not fill t he different ial wi th lubri cant up t o
t he fi ll er pl ug. The fil ler plug i s only us ed t o fill t he different ial wi th
l ubricant , and not to act as a level i ndicat or.
Fil l the di fferenti al wi th the correct amount of l ubricant .
13.

Publi s hed: 11-May-2011
Brake System - General Information -
Brake Hydraulic Fluid
CAUTION: * If t he fl uid s hown i s not avail abl e, use a low vis cos it y DOT 4 brake fluid meeti ng ISO 4925 Clas s 6 andLand Rover LRES22BF03 requirements .
ItemSpecification
Recommended hydraul ic fluid*SHELL DONAX Y B DOT4 ESL FLUID
General Specification
ItemSpecification
Front and rear cali persSingle pis ton sl iding cali persOperat ionHydrauli c, s elf adjus t ing
Front dis cVenti lat ed
Rear dis c:3.2 PetrolVenti lat ed
2.2 DieselSoli d
Parking brake typeManually appl ied cabl e operat ed s ys t emMas ter cylinder andboost er:MakeConti nent al Teves
Master cylinder typeTandem desi gn wi th i ndependent (pri mary and secondary) hydraul ic circui ts
Booster typeCompact des ign wit h t andem di aphragms 203.20 mm (8.00 i n) and 228.60 mm (9.00 in) i ndiamet er

Publi s hed: 11-May-2011
Brake System - General Information - Brake System
Des cript ion and Operat ion
COMPONENT LOCATION
ItemPart NumberDescription1-Brake pedal, boost er and mas ter cyl inder ass embly
2-Parking brake lever
3-Rear di s c brake and parking brake ass embly4-Anti -l ock Brake Sys t em (ABS) modul e and Hydrauli c Control Uni t (HCU)
5-Front dis c brake as s embly
6-ABS s peed s ens or cabl e
INTRODUCTION
Vehicle braki ng is achieved wi th a vacuum as s is t ed, hydrauli c ci rcuit connect ed via an i ntegrat ed ABS module and HCU, tot he front and rear di s c brake calipers. For increas ed s afety, t he hydraul ic s ys tem is des igned as a di agonall y s pli t dualcircuit . This provi des a pri mary and secondary braking circui t connected bet ween the mast er cyl inder and each front andoppos ing rear wheel .
The braking s ys tem provides anti -l ock control to ai d t he dri ver, and to make s ure t he vehi cle remains i n cont rol duri ng alldri vi ng condi ti ons and manouevres . The s ophis t icated ABS funct ionali ty al s o int egrates wit h other vehi cl e s oft warecont rol led s yst ems , to provide s t abi li ty as s is tance and cont rol when driving off-road.

The parking brake is a manual ly appli ed cabl e s ys t em t hat operates brake s hoes, housed wit hin the i nner diamet er of eachrear brake di sc.
FRONT AND REAR DISC BRAKES
The 3.2L i 6 vehicle i s ins t al led wit h vent il ated front and rear brake di scs . The 2.2L TD4 vehicle is i nst all ed wit h venti latedfront and sol id rear brake dis cs. Bot h t he i6 and TD4 vehicl es feature s ingle pi s ton, s lidi ng cal ipers on all brake dis cs . Foraddi ti onal i nformat ion, refer to:
Front Dis c Brake (206-03 Front Di sc Brake, Des cri pt ion and Operati on),Rear Di sc Brake (206-04 Rear Di s c Brake, Des cri pti on and Operati on).
PARKING BRAKE
The parking brake is a manual ly appli ed, cable operat ed s yst em. The RH and LH rear brake dis cs form the parki ng brakedrums , and provide the l ocat ion for the parki ng brake s hoes and components .For addit ional informat ion, refer t o: Parking Brake (206-05 Parki ng Brake and Act uat ion, Descripti on and Operat ion).
HYDRAULIC BRAKE ACTUATION
Hydrauli c brake act uati on cons is t s of the brake pedal , mast er cyl inder, HCU, and t he connect ing hydraul ic pipes and hos es.
The t andem brake mas ter cylinder wit h reservoi r is at tached to, and operat ed by t he brake boos t er. The brake mas t ercyl inder is a tandem des ign t hat suppli es pres s ure t o 2 i ndependent (pri mary and secondary) hydraul ic circui ts .For addit ional informat ion, refer t o: Hydraulic Brake Actuati on (206-06 Hydraulic Brake Act uati on, Des cri pt ion andOperat ion).
BRAKE BOOSTER
The brake boost er is vacuum operat ed and provides power as s is t ance t o t he brake hydrauli c s ys t em. The boos t er i s oft andem des ign that incorporat es 2 s eparate diaphragms . On both the gas oline and di esel models , t he vacuum required forboos t er operat ion is produced by an engine driven, vacuum pump.For addit ional informat ion, refer t o: Brake Boos ter (206-07 Power Brake Act uati on, Des cript ion and Operat ion).
ANTI-LOCK CONTROL
The anti -l ock control sys tem feat ures a Cont inental Teves Mk25E1 ABS module wit h i ntegral 4 channel HCU. The ABSmodule and HCU provide brake sys tem monit ori ng, and acti ve brake funct ions t o cont rol t he vehi cl e s tabil it y and t racti on.The ABS module al s o provides s peci fi c functi ons to as s is t t he vehi cl e duri ng off-road drivi ng.
The anti -l ock control sys tem provides t he fol lowing funct ions :
Anti -l ock Brake Sys t em (ABS)Corner Brake Control (CBC)Dynamic St abi li ty Cont rol (DSC)Electroni c Brake Force Di s tributi on (EBD)Electroni c Tracti on Control (ETC)Emergency Brake As s is t (EBA)Engi ne Drag-Torque Control (EDC)Hil l Descent Cont rol (HDC) wit h gradi ent release cont rolRoll Stabi lit y Control (RSC)Terrai n Res pons e™ sys tem int egrati on.
For addit ional informat ion, refer t o: Anti -Lock Cont rol - St abi li ty As s is t (206-09C Anti -Lock Cont rol - St abi lit y As s is t,Des cript ion and Operat ion).