2006 LAND ROVER FRELANDER 2 Transfer case

For addit ional informat ion, refer t o: Specificati ons (307-01 Aut omati c Trans mis s ion/Transaxle, Speci fi cat ions ).
Manual Transmission
Every 10 years or 150,000 miles (240,000 km): Renew manual t rans mi ss ion fl ui d.
For addit ional informat ion, refer t o: Specificati ons (308-00 Manual Trans mis s ion/Transaxle and Clutch - General
Informat ion, Speci ficat ions).
Power Transfer Unit
Every 10 years or 150,000 miles (240,000 km): Renew power t rans fer unit oi l. For addi ti onal informat ion, refer to:
(308-07B Transfer Case)
Power Trans fer Uni t - TD4 2.2L Di esel , Vehi cl es W i th: M66 6-Speed Manual Trans mis s io n AW D (Removal and
Ins tal lat ion),
Power Trans fer Uni t - TD4 2.2L Di esel , Vehi cl es W i th: M66 6-Speed Manual Trans mis s io n AW D (Removal and
Ins tal lat ion).
Differential Assembly - Rear
Every 10 years or 150,000 miles (240,000 km): Renew rear different ial oil .
For addit ional informat ion, refer t o: Specificati ons (205-02 Rear Drive Axle/Different ial, Specifi cat ions ).
Suspension and Body Mountings Check for free play i n all s us pens ion and body mounti ng rubbers . Check condit ion of s uspens ion rubber boots and gait ers .
Fuel System
Check fuel sys tem pipes , hos es and unions for chafi ng, l eaks and corros ion. Electrical Harnesses
Check al l el ect ri cal harnes s es for chafing. Oil/Fluid Leaks
Check for oil/fluid leaks . Power Steering
Check power s teering rod bal l joi nt fixi ngs , gait ers and condi ti on of bal l joi nt s an d dus t covers .Check power s teering pipes , hos es and unions for chafi ng, leaks and corros ion.
Exhaust System
Check exhaust s ys tem for l eaks , securi ty and damage. Clutch
1. Check clut ch pipes and unions for chafi ng, l eaks and corrosi on.
Fault Lamp(s) If fault l amp(s ) are ill uminat ed, t est the as s oci at ed s yst em us i ng Land Rover approv ed di agnos ti c equipment and
report findi ngs . Road Test
Carry out road t est of vehicle.
For addit ional informat ion, refer t o: Road/Roller Tes ti ng (100-00 General Informati on, Des cri pt ion and Operati on).
General
Endors e Service Record. Report any unus ual features of vehi cl e condi ti on and any addi ti onal work required.
Vehicles Operating Under Arduous Conditions
Recommended s ervi ce interval s for vehicles operat ing under arduous condit ions are de t ail ed below.
Braking System CAUTION:
When vehicles are operating under arduous conditions, the following service items mu st be carried
out every 3 months or 3,750 miles (6,000 km).
Ins pect front brake pads for wear.

Publi s hed: 11-May-2011
Manual Transmission/Transaxle and Clutch - General Information - Manual
Transaxle and Clutch
Diagnosi s and Tes ti ng
Principles of Operation
For a detail ed descripti on of the manual t rans mis s ion/t rans axl e and clut ch, refer to the relevant Des cri pti on and Operati ons ect ion i n t he works hop manual . REFER to:
Manual Trans mis s ion and Cl utch (308-00 Manual Trans mi s si on/Trans axl e and Clut ch - General Informat ion,Descri pti on and Operat ion),Clutch Cont rols (308-02 Cl utch Controls , Descripti on and Operat ion),Ext ernal Cont rol s (308-06 Manual Trans mi ss ion/Transaxle Ext ernal Cont rol s , Des cri pti on and Operati on),Four-W heel Drive Syst ems (308-07A Four-W heel Drive Sys tems , Des cript ion and Operat ion),Transfer Case (308-07B Trans fer Cas e, Descripti on and Operat ion).
Inspection and Verification
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 Inspection
MechanicalElectrical
Trans mi ss ion fl ui d l eaksClut ch fl uid l eaksMi ss i ng fi xi ngsSwit chesShift mechanis ms
W iring harnes s esSwi tches
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 , verify t he sympt om and refer t o t he Sympt om Chart.4.
Symptom Chart
• NOTE: Check trans mi ss i on fl uid l evel pri or to carrying out any further diagnosi s .REFER to: Trans mi ss i on Fl uid Level Check (308-03 Manual Trans mi ss i on/Trans axl e, General Procedures ).
SymptomPossible CauseActionSignificant effortrequi red whendownshi ft ing ors ynchroni zer cras hing
Gear s hift mechanis mGear s ynchroni zat ion i si nadequate
Check int egrit y of gear s hift mechani sm and for correcti nst all at ion. If gear s ynchroni zat ion i s inadequat e, ins tall a newt rans mis s ion. Refer t o t he new module/component ins tall ati onnot e at the top of t he DTC IndexGear jumps out ofengagement whil edri ving
W orn or broken s ynchroni zercomponent sManufact uring error(incorrect gear wheelt oothi ng or synchronizerring)
Inst all a new transmis si on, refer t o t he new module/componenti nst all at ion not e at t he top of t he DTC Index
Gears hift li nkagedoes not operat efreely (s ti ff orpart ial ly s eized)
Excess ive fricti on in leverbeari ngGearshi ft s elector cabl esas s embly damaged or wornGear s hift mechanis mPos s ible fault i nt rans mi ss i on
Check and ins tal l a new l ever bearing as neces sary. Checki ntegri ty of gears hift cabl es and mechanis m, and for correcti nst all at ion. If internal component s are s us pect , ins t al l a newt rans mis s ion, refer to the new modul e/component i ns t allat ionnot e at the top of t he DTC Index
Brief s cratching nois eduri ng gear s hifti ngInadequate gears ynchroni zat ionInst all a new transmis si on, refer t o t he new module/componenti nst all at ion not e at t he top of t he DTC Index
Leak fromt rans mis s ion hous ingLeak from breatherLeak from fi ll/drai n plugsSeali ng li p of t hei nput /out put shaft oi l seal sdamagedLeak from the s elect or s haftoi l sealLeak from cranks haft rears ealLeak from cl utch hydrauli cs
Check and recti fy flui d leaks from breather, fil l/drain plugs,s eals and clut ch hydraul ics
Cli cki ng nois es inreverse gearGear wheels chippedInst all a new transmis si on, refer t o t he new module/componenti nst all at ion not e at t he top of t he DTC Index

Publi s hed: 25-Nov-2011
Transfer Case -
Lubricants, Fluids, Sealers and AdhesivesItemLand Rover Part No.
Input s haft s pli nes grease6G92M1C27AA
Power trans fer uni t fl ui d - vehicles wi th 3.2 pet rol and 2.2 di eselLR003137Power trans fer uni t fl ui d - vehicles wi th 2.0 pet rolLR003136
C apacitiesDescriptionLubricantCapacity (liters/pints/US quarts)
Power trans fer uni tBOT 118 PLUS 75W -900.75/1.3/0.79
General Specification
ItemRatio3.2 Pet rol aut o3.750:1
2.2 Dies el manual4.533:1
2.2 Dies el aut o3.329:12.0 Pet rol aut o2.583:1
Torque Specifications
DescriptionNmlb-ft
Axle mount ing bracket bolt s2418Oi l drain pl ug3526
Oi l fil ler plug3526
Pini on nut4835Power trans fer uni t front mount ing bracket heat s hiel d107
Power trans fer uni t bracket t o engine block bolt s6548
Power trans fer uni t bracket t o power trans fer uni t bol ts6548Power trans fer uni t to trans mi s si on hous i ng bol ts6548

Publi s hed: 11-May-2011
Transfer Case - Transfer Case
Des cript ion and Operat ion
For addit ional informat ion, refer t o: Four-W heel Drive Sys tems (308-07A Four-W heel Drive Sys tems, Des cript ion andOperat ion).

Publi s hed: 11-May-2011
Transfer Case - Transfer Case
Diagnosi s and Tes ti ng
Principles of Operation
For addit ional informat ion.
REFER to: Manual Transaxle and Clutch (308-00 Manual Transmis si on/Trans axl e and Cl ut ch - General Informat ion,
Diagnosi s and Tes ti ng).

Publi s hed: 11-May-2011
Transfer Case - Transfer Case Fluid Level Check
General Procedures CAUTION: The fluid fi ller plug is not a flui d level pl ug.
1. W ARNING: Make sure t o s upport the vehicle wit h axle
s tands .
Rais e t he vehicle on a li ft .
1.
Remove t he engi ne undershi eld.
Refer t o: Engi ne Unders hi eld (501-02 Front End Body Panel s ,
Removal and Ins tall ati on).
2. 3. CAUTION: Make s ure that the area around t he
component i s cl ean and free of foreign mat eri al .
3.
4. CAUTION: The fluid fi ller plug is not a flui d level pl ug.
Top-up t he t rans fer cas e wit h recommended fl uid, unti l the fluid is
l evel wit h bot tom of fil ler plug hol e. Remove 120 ml for correct fl uid
capacit y as s hown i n Specificati on s ect ion.
Refer t o: Specificati ons (308-07B Trans fer Cas e, Specificati ons ).
4.
5. CAUTION: Replace t he washer.
Inst all t he fl uid fil ler plug.
T orque: 35 Nm 5.
Inst all t he engi ne undershi eld.
Refer t o: Engi ne Unders hi eld (501-02 Front End Body Panel s ,
Removal and Ins tall ati on).
6.

Publi s hed: 11-May-2011
Transfer Case - Power Transfer UnitI6 3.2L Petrol
Removal and Inst all ati on
Removal
• NOTE: Removal s t eps in t his procedure may cont ain i nst all ati on det ail s.
1. W ARNING: Do not work on or under a vehi cle s upported onl y
by a jack. Al ways support t he vehi cl e on s afet y s tands .
Rais e and s upport t he vehi cl e.
1.
Refer t o: Dri ves haft - Vehicles W it hout : Dies el Part icul ate Fi lt er (DPF) (205-01 Driveshaft, Removal and Ins tal lati on).
2.
Refer t o: Cat alyt ic Converter (309-00A Exhaus t Syst em - I6 3.2L
Petrol, Removal and Ins tall ati on).
3.
Refer t o: Front Halfs haft RH (205-04 Front Dri ve Halfs haft s , Removal
and Inst all at ion).
4. T orque:
65 Nm 5.
6.

Publi s hed: 11-May-2011
Transfer Case - Power Transfer UnitTD4 2.2L Diesel, Vehicles With: M66
6-Speed Manual Transmission AWD
Removal and Inst all ati on
Removal
1. W ARNING: Make sure t o s upport the vehicle wit h axles tands .
Rais e t he vehicle on a li ft .
1.
Remove t he dri ves haft .
Refer t o: Dri ves haft - Vehicles W it hout : Dies el Part icul ate Fi lt er(DPF) (205-01 Driveshaft, Removal and Ins tal lati on).
2.
Remove t he cat alyti c convert er.
Refer t o: Cat alyt ic Converter - Vehicles W it hout : Di es el Part iculateFil ter (DPF) (309-00B Exhaus t Syst em - TD4 2.2L Di es el, Removaland Inst all at ion).
3.
Remove t he lower engi ne s tabil izer bar.
Refer t o: Engi ne Lower Support Ins ulat or (303-01A Engine - I6 3.2LPetrol, Removal and Ins tall ati on).
4.
Remove t he RH halfs haft.
Refer t o: Front Halfs haft RH (205-04 Front Dri ve Halfs haft s , Removaland Inst all at ion).
5.
6.