LAND ROVER FRELANDER 2 2006 Repair Manual

5.
NOTE: Dis card t he ret aining cl ip.
5. Speci al Tool (s ):
303-D121 6.
Installation 1. CAUTION: Extreme cleanli nes s mus t be exercis ed when
handl ing t hese components .
Clean and i nspect the components for det eri orati on.
1.
Inst all t he inner CV boot ont o t he halfshaft .
2.
3. NOTE: Ins t al l a new retaini ng clip.
Inst all t he inner CV joi nt inner ont o t he halfshaft .
3.
4. CAUTION: Make s ure that thes e component s are ins tall ed t o
t he noted removal pos it ion.
Inst all t he inner CV joi nt out er ont o t he halfshaft.
4.
Pack the i nner CV joint wi th the grease suppli ed.
5.
6. NOTE: Ins t al l new ret aining cl ips .
Secure t he inner CV joi nt boot t o t he inner CV joint.
6.
Inst all t he hal fs haft .
7.

Refer t o: Rear Hal fs haft LH (205-05 Rear Dri ve Halfs haft s , Removaland Inst all at ion).

Publi s hed: 11-May-2011
Rear Drive Halfshafts - Outer Constant Velocity (CV) Joint Boot
Removal and Inst all ati on
Special T ool(s)
303-D121Pull er, General Purpose
Removal
• NOTE: The outer Const ant Veloci ty joint mus t not be removed from t he s haft. The i nner joint and gait er have t o beremoved t o faci lit ate gai ter repl acement of t he out er C. V. gai ter. The inner and out er gai ters are suppli ed toget her as akit .
1. W ARNING: Make sure t o s upport the vehicle wit h axles tands .
Rais e and s upport t he vehi cl e.
1.
Remove t he hal fs haft .
Refer t o: Rear Hal fs haft LH (205-05 Rear Dri ve Halfs haft s , Removaland Inst all at ion).
2.
3. NOTE: Dis card t he ret aining cl ips .3.
4. NOTE: Dis card t he ret aining cli ps.4.

5.
6.
NOTE: Dis card t he ret aining cl ip.
6. Speci al Tool (s ):
303-D121 7.
Installation 1. CAUTION: Extreme cleanli nes s mus t be exercis ed when
handl ing t hese components .
Clean and i nspect the components for det eri orati on.
1.
Inst all t he inner and out er CV boots ont o t he hal fs haft .
2.
3. NOTE: Ins t al l a new retaini ng clip.
Inst all t he inner CV joi nt inner ont o t he halfshaft .
3.
4. CAUTION: Make s ure that thes e component s are ins tall ed t o
4.

t he noted removal pos it ion.
Inst all t he inner CV joi nt out er ont o t he halfshaft.
Pack the i nner CV joint wi th the grease suppli ed.5.
Pack the out er CV joi nt wit h t he grease s uppli ed.6.
7. NOTE: Ins t al l new ret aining cl ips .
Secure t he inner CV joi nt boot t o t he inner CV joint.
7.
8. NOTE: Ins t al l new ret aining cl ips .
Secure t he outer CV joint boot to t he outer CV joint .
8.
Inst all t he hal fs haft .
Refer t o: Rear Hal fs haft LH (205-05 Rear Dri ve Halfs haft s , Removaland Inst all at ion).
9.

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).

Publi s hed: 11-May-2011
Brake System - General Information - Brake System
Diagnosi s and Tes ti ng
Principle of Operation
For a detail ed descripti on of the brake s ys t em, refer t o t he rel evant Des cript ion and Operat ion secti on in the workshopmanual. REFER to:
Brake Syst em (206-00 Brake Sys t em - General Informat ion, Des cript ion and Operat ion),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 (206-05 Parki ng Brake and Actuat ion, Descri pti on and Operat ion),Hydraul ic Brake Act uati on (206-06 Hydraul ic Brake Act uati on, Des cript ion and Operat ion),Brake Boost er (206-07 Power Brake Act uat ion, Des cript ion 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 damage and s ys t em i ntegri ty.2.
Visual Inspection
MechanicalElectricalBrake mast er cyl inderBrake cali per pi st on(s )Brake di scsW heel bearingsBrake padsPower brake boos t erVacuum pumpBrake pedal li nkageBrake boos ter vacuum hos eTires
Damaged or corroded wiring harnes sBrake mas ter cyli nder fluid level s wi tch
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 concern and refer t o t he Sympt om Chart.4.
Road Test
Carry out a road tes t to compare act ual vehicl e braking performance wi th the performance s t andards expected by t hedri ver. The abi li ty of t he t est driver to make val id compari s ons and det ect performance defi cienci es wil l depend onexperience.
The dri ver s hould have a t horough knowl edge of brake s ys t em operat ion and accept ed general performance guideli nes tomake good comparis ons and detect performance concerns .
An experienced brake t echnician will al ways es t abl is h a route that wi ll be us ed for all brake di agnos is road t es t s . Theroads s elected will be reasonably s moot h and level. Gravel or bumpy roads are not sui table because the s urface does notall ow t he ti res t o grip t he road equall y. Crowned roads s houl d be avoided becaus e of t he large amount of wei ght s hifted tot he low set of wheels on t his type of road. Once the route is es tabl is hed and cons ist ent ly us ed, the road s urface vari ablecan be eli minat ed from t he t es t resul ts .
Before a road tes t, obt ain a compl et e des cript ion of t he cus t omer concerns or s uspected condit ion. From t he des cript ion,t he techni cian's experience wi ll all ow t he techni cian t o mat ch pos s ibl e caus es wi th s ympt oms. Certai n components wil l bet agged as pos si ble s us pect s whil e others wil l be eli minated by the evidence. More i mport ant ly, t he cus t omer des cri pt ioncan reveal uns afe condit ions which s hould be checked or correct ed before the road t est . The descri pti on wil l als o help formt he bas i c approach t o t he road tes t by narrowi ng t he concern t o s peci fi c components , vehicle s peed or condit ions .
Begin t he road tes t wit h a general brake performance check. Keepi ng t he des cri pti on of the concern in mind, t est t hebrakes at different vehicle s peeds usi ng both light and heavy pedal pres s ure.
If the concern becomes evident duri ng thi s check, verify it fit s t he descri pti on given before the road t est . If t he concern isnot evi dent , att empt to dupl icate t he condi ti on us ing t he informat ion from the des cri pt ion.
If a concern exi st s , refer t o t he Symptom Chart.
Symptom Chart
SymptomPossible CauseAction
Brakes nois yBrake padsBrake dis csGO t o Pinpoint Test A.
Vibrati on when brakes areappliedW heels /t ires out of bal anceW heel hub nut s loos eBrake cal iper mounti ng bolt s loos eBrake padsForeign mat eri al /s crat ches /corrosi onon brake dis c contact surfacesExcess i ve brake dis c t hicknes s
GO t o Pinpoint Test B.

1
1
SymptomPossible CauseAction
variat ionExcess i ve brake dis c runoutW heel beari ng wear or fail ureSus pensi on bushi ng wear or failureSt eeri ng bus hing wear or failure
The brakes pull or dri ftTi re pres sures/wearBrake cal ipersBrake padsBrake dis csW heel al ignment adjus tmentW heel beari ngSus pensi on bushi ngs and bal l joint s
GO t o Pinpoint Test C.
The pedal feels s pongyAir in brake s ys t emLeak i n hydraulic sys temBrake boos t er/mas ter cyl inderfail ureBrake pads
GO t o Pinpoint Test D.
The pedal goes down fastAir in brake s ys t emLeak i n hydraulic sys temBrake boos t er/mas ter cyl inderBrake pads
GO t o Pinpoint Test E.
The pedal goes downs lowl yAir in brake s ys t emBrake boos t er/mas ter cyl inderGO t o Pinpoint Test F.
Exces s ive brake pedaleffortBrake padsBrake boos t erGO t o Pinpoint Test G.
Brake l ockup duri ng li ghtbrake pedal forceBrake padsBrake cal ipersGO t o Pinpoint Test H.
Brakes dragParking brake controlappl ied/mal functi onSei zed parking brake cablesSei zed cal iper sl ide pi nsSei zed brake cal iperBrake boos t erPedal gear
GO t o Pinpoint Test I.
Exces s ive/Errat ic brakepedal t ravelHydraul ic s ys temBrake padsBrake dis csHub and bearing as s embly
GO t o Pinpoint Test J.
The red brake warni ngi ndi cat or is always onFl uid l evelBrake fl uid l evel s ensorParking brake controlEl ect ri cal circui t
Fi ll the sys tem t o s pecificati on. Check for l eaks .Ins tall a new brake mas t er cyli nder fluid res ervoiras requi red.REFER t o: Brake Mas ter Cyli nder (206-06 HydraulicBrake Act uati on, Removal and Ins tal lati on).Check parking brake operat ion/elect rical circui ts .REFER t o: Parking Brake (206-05 Parki ng Brake andAct uat ion, Diagnosi s and Test ing).
Slow or incompl ete brakepedal returnBrake pedal bindi ngBrake boos t er/mas ter cyl inderGO t o Pinpoint Test K.
Pinpoint Tests
PINPOINT TEST A : BRAKES NOISY
T ESTCO NDIT IONSDET AILS/RESULT S/ACT IONS
A1: INSPECT BRAKE PADS
Ins pect the condi ti on of the front and rear brake pads . Check for damage to any ant i-s queals hims .
Are the brake pads OK?YesGO to A2.NoCLEAN or INSTALL new brake pads as requi red.REFER to: Brake Pads (206-03 Front Di sc Brake, Removal and Ins tal lati on) /Brake Pads (206-04 Rear Di s c Brake, Removal and Ins t allat ion).Test t he s yst em for normal operat ion.
A2: INSPECT BRAKE DISCS
Ins pect the brake di s cs for exces si ve corros ion, wear or di s c thi ckness variat ion.
Does exces si ve corros ion, wear or di s c thi ckness variat ion exis t?YesINSTALL new brake di s cs and brake pads as required.REFER to: Brake Pads (206-03 Front Di sc Brake, Removal and Ins tal lati on) /Brake Di sc (206-03 Front Di s c Brake, Removal and Ins t allat ion) /