2006 LAND ROVER FRELANDER 2 clutch

Any s praying s houl d preferably be carri ed out in venti lat ed boot hs which i ncorporat e faci li ti es for removi ng vapors ands pray dropl et s from the breathing zone.
W ear appropri at e gl oves , eye and res pirat ory protecti on.
Antifreeze
May be flammabl e when undilut ed.
Vapors may be gi ven off from coolant anti freeze when heat ed. Avoid breathi ng thes e vapors .
Anti freeze may be absorbed through t he s kin i n t oxi c or harmful quanti ti es. Ant ifreeze, i f s wal lowed, can be fat al; SEEKIMMEDIAT E MEDICAL AT T ENT ION.
Battery Acids
See als o Al kal is and Acids .
Gas es releas ed duri ng bat t ery charging are expl osi ve. Al ways remove t he batt ery from t he vehi cl e pri or to chargi ng. Neverus e naked flames or al low s parks near charging or recentl y charged bat t eries . NEVER add aci d t o a bat tery, t he chemicalreacti on produced wil l be vi olent and expl os i ve. In cases of eye contact, was h affected area wit h copious amount s of wat erand SEEK IMMEDIAT E MEDICAL AT T ENT ION.
Make s ure t here i s adequat e vent il ati on during bat tery charging, obs erve NO SMOKING POLICY .
Brake Pads and Linings
Always fit t he correct grade and s peci fi cat ion of brake pads and l inings . W hen renewi ng pads and lini ngs , always repl aceas complete axl e s ets .
Brake and Clutch Fluid
Splas hes to t he s kin and eyes are irri tat ing and i n t he long t erm can be damagi ng, avoid prolonged s ki n cont act. In casesof eye cont act , wash affect ed area wi th copious amount s of water and SEEK IMMEDIATE MEDICAL ATTENTION.
Chemical Materials
All chemical materials should al ways be used wit h caut ion and st ored and handled wi th care. They may be toxic, harmful,corros ive, irri tant or highly fl ammable and gi ve ri se to hazardous fumes and dus t s.
The effect s of exces s ive expos ure to chemi cal s may be i mmediat e or delayed; briefl y experienced or permanent ;cumulati ve; s uperficial; life t hreatening; or may reduce l ife expect ancy.
Chemical Materials - Do's
Do careful ly read and observe hazard and precaut ion warnings given on material cont ai ners (labels ) and in anyaccompanyi ng leaflets , pos ters or ot her ins truct ions . Material heal th and safet y data s heet s can be obtained frommanufacturers .Do remove chemi cal mat eri al s from the s kin and cl othing as soon as pract icable after s oil ing. Change heavily soi ledclothi ng and have it cleaned.Do organi se work pract ices and prot ect ive clot hing t o avoi d s oil ing of t he s ki n and eyes .Do avoid breat hing vapors , aeros ols , dus t s or fumes ; inadequat e container labell ing; fi re and expl os i on hazards .Do was h before job breaks, before eati ng, s moking, dri nki ng or usi ng t oi let faci lit ies when handli ng chemicalmat erial s.Do keep work areas clean, unclut tered and free of s pi ll s.Do s t ore chemical materials according to nat ional and local regul at ions .Do keep chemical materi als out of t he reach of chi ldren.
Chemical Materials - Do Not
Do Not mi x chemical materials except under the manufact urers ins truct ions ; s ome chemicals can form ot her toxic orharmful chemi cal s, gi ve off t oxi c or harmful fumes or become explos ive when mixed t oget her.Do Not s pray chemical materials , part icularly t hose bas ed on s olvents , i n confined spaces , for example when peopleare ins ide a vehicle.Do Not apply heat or fl ame t o chemical materi als except under the manufact urers ins truct ions . Some are hi ghlyfl ammable and some may rel ease toxic or harmful fumes .Do Not l eave contai ners open. Fumes given off can bui ld up to t oxic, harmful or explos ive concentrati ons . Somefumes are heavier than ai r and wil l accumulate in confi ned areas s uch as pi ts .Do Not t rans fer chemical materi als t o unlabell ed cont ainers .Do Not clean hands or cl othing wit h chemicals . Chemical s , parti cul arly sol vent s and fuel s, wi ll dry ski n and maycaus e i rrit ati on leading t o dermat it is or be abs orbed t hrough t he s ki n i n t oxi c or harmful quanti ti es .Do Not us e empt ied containers for ot her mat eri al s except when t hey have been cleaned under s upervis edcondi ti ons .Do Not s niff or smel l chemi cal mat eri al s , even brief expos ure to hi gh concentrat ions of fumes can be toxic orharmful.
Corrosion Protection Materials
Some corrosi on prot ect ion mat eri als are highly flammabl e – obs erve NO SMOKING POLICY.
Thes e materials are vari ed and the manufact urers ins truct ions mus t always be foll owed. The mat eri als may contai ns olvent s , res ins or petroleum product s. Skin and eye cont act s houl d be avoided. They s hould only be s prayed in condit ionsof adequate vent il at ion and not i n confined s paces .

DT C
Description Possible Cause Action
P073F-00 Unabl e t o engage gear 1 Cont act resi s tance in the
terminals Sol enoi ds st uck in t he on/off
pos it ion. Mechanical fault i n the
trans mi ss i on P0741-00
Torque convert er clutch
s ol enoi d circui t
performance/s tuck off Cont act resi s tance in the
terminals Torque convert er cl ut ch lock
up cont rol s ol enoi d (SLU)
ci rcuit : short ci rcuit t o ground Torque convert er cl ut ch lock
up cont rol s ol enoi d (SLU)
ci rcuit : short ci rcuit t o power Torque convert er cl ut ch lock
up cont rol s ol enoi d (SLU)
ci rcuit : open ci rcuit Torque convert er cl ut ch lock
up sol enoi d (SLU) s t uck i n off
pos it ion Int ernal t rans mi ss i on cont rol
modul e (TCM) fault Refer to the warrant y pol icy and procedures
manual i f the t rans mis s ion or t he TCM i s
sus pect .
P0742-00 Torque convert er clutch
s ol enoi d circui t st uck on Cont act resi s tance in the
terminals Torque convert er cl ut ch lock
up cont rol s ol enoi d (SLU)
ci rcuit : short ci rcuit t o ground Torque convert er cl ut ch lock
up cont rol s ol enoi d (SLU)
ci rcuit : short ci rcuit t o power Torque convert er cl ut ch lock
up cont rol s ol enoi d (SLU)
ci rcuit : open ci rcuit Torque convert er cl ut ch lock
up sol enoi d (SLU) s t uck i n on
pos it ion Int ernal t rans mi ss i on cont rol
modul e (TCM) fault P0744-68
Torque convert er clutch
s ol enoi d circui t
int ermi tt ent Engine st all ed Mechanical fault i n engi ne Carry out a compl ete read for related engi ne
DTCs . Recti fy as necess ary.
P074A-00 Unabl e t o engage gear 2 Cont act resi s tance in the
terminals Sol enoi ds st uck in t he on/off
pos it ion Mechanical fault i n the
trans mi ss i on Check t rans mis s ion flui d level and condit ion.
Refer to the warrant y pol icy and procedures
manual i f the t rans mis s ion is s us pect.
P074B-00 Unabl e t o engage gear 3 Cont act resi s tance in the
terminals Sol enoi ds st uck in t he on/off
pos it ion Mechanical fault i n the
trans mi ss i on P074C-00
Unabl e t o engage gear 4 Cont act resi s tance in the
terminals Sol enoi ds st uck in t he on/off
pos it ion Mechanical fault i n the
trans mi ss i on P074D-00
Unabl e t o engage gear 5 Cont act resi s tance in the
terminals Sol enoi ds st uck in t he on/off
pos it ion Mechanical fault i n the
trans mi ss i on P074E-00
Unabl e t o engage gear 6 Cont act resi s tance in the
terminals Sol enoi ds st uck in t he on/off
pos it ion Mechanical fault i n the
trans mi ss i on P0777-00
Pres s ure control s olenoid B
s tuck on Shi ft s olenoid No. 2 st uck in
the on pos it ion Refer to the warrant y pol icy and procedures
manual i f the t rans mis s ion is s us pect.

Check t hat the flui d level is t o t he mi d-way mark between the MAX and MIN marks on t he fluid res ervoir, t op-up i fneces s ary.Clean t he area around the res ervoi r fi ll er cap, remove cap.
CAUTION: Do not fill reservoir above the MAX mark.
If necess ary, t op-up us ing t he recommended fluid to the mid-way mark on the reservoir.For addit ional informat ion, refer t o: Specificati ons (211-02 Power St eering, Specificati ons).Ins t all the res ervoir fill er cap.
Windshield Washer Reservoir
Remove the winds hi eld was her res ervoir fill er cap.Top-up t he res ervoir us ing a mi xt ure of an approved wi nds hiel d was her flui d and water unti l the level i s t o thebott om of t he gauze fil ter i n t he res ervoir fil ler neck.Ins t all the res ervoir fill er cap.
Engine Oil and Filter
CAUTION: For vehi cl es operati ng under arduous condi ti ons s ee relevant s ecti on.
Every 6 months or 7,500 miles (12,000 km): NAS and Gulf markets Renew engi ne oil and filt er.For addit ional informat ion, refer t o: Specificati ons (303-01A Engine - I6 3.2L Petrol, Speci fi cat ions).
Air Filtering
CAUTION: For vehi cl es operati ng under arduous condi ti ons s ee relevant s ecti on.
1. Every 2 years or 30,000 miles (48,000 km): Replace the ai r cl eaner element .For addit ional informat ion, refer t o: Air Cl eaner (303-12A Int ake Ai r Dis t ri but ion and Fi lt ering - I6 3.2L Petrol , Removal andIns t allat ion).
Automatic Transmission
Every 10 years or 150,000 miles (240,000 km): Renew automat ic t rans mis s ion flui d.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 - GeneralInformat 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 addit ional informat ion, refer t o: Specificati ons (205-03, Speci fi cat ions ).
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

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.

Inexperi enced off-road dri vers may benefi t from t he automat ic as s is tance of t he Terrai n Respons e s yst em and t he driverinformat ion. Experienced off-road drivers can s elect the specific programs for ext reme condit ions t o acces s cont rol over t hevehi cl e s yst ems (for example; accel erator pedal maps , t rans mis s ion s hift maps , traction s ett ings ) which are not access i bl eon vehicles wi thout Terrai n Res pons e.
Stop/St art Vehicl es - From 2010 MY
Acti vat ion of t he Terrai n Res pons e s peci al programs wi ll deact ivate the St op/St art syst em.
However, if Terrain Res pons e is acti vat ed when t he engi ne is shut down in a Stop/St art cycl e t he engi ne wil l aut omat ical lyres t art . If duri ng thi s event t he Stop/Start sys tem cannot detect the driver's occupancy, for example ei ther t he dri ver’ss afety bel t or door i s unlatched, the engine wi ll not res t art . The St op/St art s yst em will reques t t he driver t o depres s theclutch t o rest art t he engine. The dri ver wi ll be i nformed of t his by ‘RESTART REQUIRED PRESS CLUTCH’ being di spl ayed i nt he mes sage center.For addit ional informat ion, refer t o: Starti ng Sys t em (303-06C Starti ng Syst em - TD4 2.2L Di es el, Vehicles Bui lt From:01-03-2009, Descripti on and Operat ion).
TERRAIN RESPONSE ROTARY CONTROL AND MODULE
ItemPart NumberDescription1-Hil l Des cent Cont rol (HDC) s wi tch
2-Special programs off
3-Gras s /Gravel/Snow program4-Rot ary cont rol
5-Mud/rut s program
6-Sand program7-Dynami c Stabil it y Control (DSC) s wit ch
Each program is denoted by a s ymbol whi ch repres ent s t he t errai n encountered. The rotary cont rol wi ll only s elect the las tprogram in it s direct ion of rotat ion. Further rot ati on of the control in ei ther direct ion, once the l ast program has beens elect ed, wil l have no effect, for exampl e; once 'Sand' has been s elect ed, furt her rotat ion i n a clockwis e direct ion wil lret ain 'Sand'.
The cont rol module and rot ary cont rol i s connected vi a a harnes s connector which al so cont ains t he wiring for the HDC andDSC s wit ches and the i ll uminati on circuit s . The cont rol module and rotary cont rol uses 4 of t hes e wi res for 12V bat t erys uppl y (i gnit ion - only when the i gni ti on is on) a ground and high s peed CAN bus (pos i ti ve and negat ive).
PRINCIPLES OF OPERATION
The fol lowing vehicl e s ub-s ys t em control modul es are us ed for t he Terrain Res pons e sys tem:
Engi ne management - Engine Cont rol Module (ECM)Trans mis s ion control - Transmis s ion Control Modul e (TCM) (automat ic t rans mi ss ion only)Acti ve on-demand coupli ng cont rol moduleBrake s ys tem - Anti -l ock Brake Sys t em (ABS)/Dynami c Stabil it y Control (DSC)/Electroni c Tracti on Control (ETC)/ Hi llDes cent Control (HDC) - ABS module

However, when the front and rear axl es st art t o rotat e at different s peeds , t he s wash-pl ate rot at es rel ati ve to the roll erswhich generat es the hydrauli c pres s ure. Thi s pres s ure i s us ed to force the opposi ng clut ch pl ates t oget her, i ncreas ing thet ransmis s ion of t orque t o the rear axl e. As the di fference in axl e s peed i ncreases the hydrauli c pres sure pushes t he clut chplat es further together t o increas e t he t orque to the rear axl e.
A control val ve/axi al s olenoid cont rols the amount of pres s ure appli ed to the clut ch plat es , and hence the amount oft orque transmit ted t o t he rear wheels . Clos e manufact uring t olerances and except ional ly low component wear ens uret orque cont rol remai ns accurat e t hroughout t he vehi cl e's l ife.
Mechanical Hydraulic Pump - Generation 4 Couplings - Vehicles from 2009MY
The Generati on 4 coupl ing does not us e the swas h pl at e t o mechanical ly rais e hydrauli c pres s ure; ins tead, a new hydraul icpump i s used to generat e hydrauli c pres sure and force the cl utch plat es toget her. The removal of t he s was h plat e all ows alarger overal l cl ut ch plat e s urface area, whi ch in t urn reduces t he hydrauli c pres sure requi rement. The press ure required toachi eve 1500Nm (1106 l b ft ) has been reduced from 100 Bar for Generat ion 3 coupli ngs to 40 Bar for Generati on 4coupl ings.
The posi ti oni ng of the Generat ion 4 coupl ing's i nput and output remains t he s ame as t he Generati on 3 coupl ing, asdescribed above.
By-pass Valve
On very low fricti on s urfaces, driveli ne drag t orque can occur, for exampl e:
revers e t orque from engi ne braking, orforced movement of t he dri ves haft by t he front wheel s .
This can i nfluence rear wheel s peed, maki ng it i mpos si ble t o determine the t rue fricti on capabil it y of the rear wheel s, bydis t orti ng t he wheel s peed s ignal. To prevent thi s, t he acti ve on-demand coupli ng is des i gned t o open i mmediat el y inres ponse to a s tabil it y cont rol event . This i s achi eved by a by-pass val ve ins tant ly reducing sys tem pres s ure t o nomi nal .
To balance the 4 bar bas e press ure (s ee below for detai ls ), t he Generati on 3 coupling us es a large Bel levill e s pri ng to forcet he cl utch plat es clear of each ot her t o prevent torque transmis si on t hrough the coupli ng. Even at 0°C, t orque t rans mis s ionis reduced from 300 Nm to Zero wi thi n 10 ms . The Generat ion 4 coupling however, does not require a Bel lvil le s pri ng t os eparate t he plat es as t he coupli ng does not have a si gni fi cant bas e pres s ure pus hi ng t he plates together.
Accumulator
The further t he cl utch pl at es have to move in order to contact each other, t he longer it t akes to di spl ace the hydrauli c fl uidneces s ary t o buil d pres s ure and t rans mit torque. To count er thi s, t he Generati on 3 coupling incorporates an accumulat or.This retains a nominal 4 bar pres sure wi thin the hydraul ic circui t. Al though thi s is not enough pres sure t o caus e s i gni fi cantt orque transmis s ion t hrough the coupli ng, i t forces t he plat es very clos e t oget her so that very l it tl e fluid di s pl acement i srequired t o achi eve full engagement and maxi mum t orque t rans fer. Ful l torque t rans miss i on can be achieved i n 150 ms .
On Generat ion 4 coupli ngs , t he 150ms act ivat ion t ime is achieved through the us e of a Bel lvil le s pri ng t hat acts to pus ht he plates t ogether (wi thout caus i ng si gnifi cant t orque t rans mis s ion t hrough t he coupl ing). As t he pump i s notcont inuousl y us ed to create t his bas e pres s ure (as i t was wit h Generat ion 3 coupli ng), improvement s i n fuel economy havebeen achi eved.
Wet Clutch Pack
The clutch pack is made up of 7 pairs of plat es ; t he inner dis cs are produced from hardened st eel wit h t he out er dis csmanufactured from s t eel wi th a s int ered face. The clutch pl ates operat e in trans mi s si on fl uid.
Torque t rans mis s ion acros s t he clutch pack is li mit ed t o 1500 Nm (1106 lb ft ). This ens ures t he l ower gears ret ai n anelement of front-wheel -drive for t ract ion s t abi lit y. W i thin the hi gher gears the coupl ing i s t heoreti call y capabl e oft ransmit ti ng all t he dri ve to the rear axle; al though condit ions woul d have to be ext reme for t his t o occur.
PRINCIPLES OF OPERATION
Generation 3 Couplings - up to 2009MY
An i nt ernal electroni cal ly-controll ed pump provides hydrauli c pre-charge pres sure wit hin the coupling. The pre-chargepres s ure s upplies t he requi red operat ing pres s ure to the clut ch plates to el imi nat e i nit ial wheel -s pin as the vehicleaccelerates from s tandst il l.
In conjunct ion wi th the pre-charge pres s ure a mechanical hydraul ic pump operates wi thi n the cl utch plat es to s upply thecoupl ing's mai n hydraulic operat ing pres sure. The mechanical pump is funct ioned by the 'i nput ' and 'output' of t he coupli ng:
input - dri ves haft connect ion from the front axle,output - different ial connecti on to the rear axl e.
Any s peed di fference bet ween t he front and rear axl es wil l st art t he operat ion of t he mechanical hydraul ic pump. Theamount of hydrauli c pres s ure appli ed to the cl ut ch pack by the pump det ermines the gap bet ween t he cl utch plat es. Forexampl e, the great er the hydraul ic pres s ure, t he s maller t he gap between t he plat es and s ubs equent ly t he great er thet orque transmit ted t hrough t he coupli ng from the front axle t o t he rear axle.
This mai n hydrauli c pres sure is des i gned t o t rans mit the t orque for tract ion demands of off-road drivi ng, and t o provi delock-up as requi red.
Generation 4 Couplings - from 2009MY
The Generati on 4 coupl ing s t il l us es an el ect ri cal ly-controlled pump to provide hydrauli c pre-charge to el imi nat e wheel-s pinfrom st ands t il l; however, the s ame pump is al s o used to provi de t he coupli ng's mai n hydraul ic operat ing press ure.

Publi s hed: 11-May-2011
Front Drive Axle/Differential - Front Drive Axle and Differential
Des cript ion and Operat ion
For addit ional informat ion, refer t o: Trans mis s ion Des cri pt ion (307-01 Aut omati c Trans mis s ion/Trans axle, Des cript ion andOperat ion).
For addit ional informat ion, refer t o: Manual Trans mi ss i on and Clutch (308-00 Manual Transmis s ion/Trans axle and Cl ut ch -General Informat ion, Descri pti on and Operat ion).

5. CAUTIONS:
Be prepared t o collect es caping flui ds .
Make s ure that all openings are sealed.
5.
All vehicles
6. CAUTION: Make s ure that all openi ngs ares ealed.6.
Installation
All vehicles
To i nst all , revers e t he removal procedure.1.
Bleed t he brake s ys tem.
Refer t o: Brake Syst em Bl eedi ng (206-00 Brake Syst em - GeneralInformat ion, General Procedures).
2.
Vehicles with manual transmission
Bleed t he clut ch sys t em.
Refer t o: Clutch Sys tem Bleeding (308-00 ManualTrans mi ss ion/Transaxle and Clut ch - General Informati on, GeneralProcedures ).
3.