gearbox LAND ROVER FREELANDER 2001 Workshop Manual

AUTOMATIC GEARBOX - JATCO
44-32 REPAIRS
Hose - fluid cooler
$% 44.24.13
This procedure is identical for both feed and return
hoses.
Remove
1.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
2.Position container to collect fluid spillage.
WARNING: Observe due care when draining
gearbox fluid as the fluid can be very hot.
3.Disconnect hose from fluid cooler and discard
'O' ring.
CAUTION: Always fit plugs to open
connections to prevent contamination.
4.Loosen union and remove hose from gearbox.
5.Remove and discard 'O' ring.Refit
1.Wipe union and pipe ends using a lint free cloth.
2.Lubricate new 'O' ring with clean transmission
fluid and fit 'O' ring to hose.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
3.Position hose to fluid cooler but do not fully
tighten union.
4.Position hose to gearbox and tighten union to
18 Nm (13 lbf.ft).
5.Tighten fluid cooler hose union to 18 Nm (13
lbf.ft).
6.Top-up gearbox fluid level.

+ MAINTENANCE, MAINTENANCE,
Automatic Gearbox – JATCO.
7.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
8.Remove container.
M44 1639

DRIVESHAFTS
47-2 REPAIRS
12.Remove 2 bolts securing damper to hub.
13.Release hub from damper.
14.Release drive shaft from hub.
15.Position container to catch oil spillage
16.Secure LRT-54-026 to drive shaft inboard joint.
Using a lever, release drive shaft from gearbox.
17.Remove drive shaft.
CAUTION: Care must be taken not to
damage oil seal when removing drive shaft
from gearbox
18.Remove and discard circlip from drive shaft.Refit
1.Inspect gearbox seal for signs of wear or
damage.
2.Wipe drive shaft ends, gearbox oil seal and
hub.
3.Lubricate oil seal running surfaces.
4.Fit new circlip to drive shaft.
5.Fit drive shaft ensuring circlip is fully engaged.
CAUTION: Drive shaft must be fitted with
care to prevent damage to gearbox oil seal.
6.Position drive shaft in hub.
7.Fit new hub nut but do not tighten at this stage.
8.Fit hub to damper, fit nuts and bolts and tighten
to 205 Nm (150 lbf.ft).
9.Position caliper to brake disc fit bolts and
tighten to 100 Nm (74 lbf.ft).
10.Clean ABS sensor and mating face.
11.Lubricate ABS sensor with anti-seize grease.
12.Fit ABS sensor .
CAUTION: Ensure ABS sensor is fully
located into hub, so that sensor touches
reluctor ring.
13.Position ABS harness and brake hose in
bracket and secure with clip.
14.Fit splash shield and secure with bolts.
15.Tighten front hub nut to 400 Nm (295 lbf.ft).
16.Stake front hub nut.
17.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
18.Check and top up oil level as required.

+ MAINTENANCE, MAINTENANCE,
Manual Gearbox – PG1.

+ MAINTENANCE, MAINTENANCE,
Manual Gearbox – GETRAG.

+ MAINTENANCE, MAINTENANCE,
Automatic Gearbox – JATCO.
19.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
20.Remove stands and lower vehicle.
21.Connect battery earth lead.

DRIVESHAFTS
47-4 REPAIRS
12.Remove 2 bolts securing damper to hub.
13.Release hub from damper.
14.Release drive shaft from hub.
15.Position container to catch oil spillage.
16.Secure LRT-54-026 to drive shaft inboard joint.
Using a lever, release drive shaft from gearbox.
17.Remove drive shaft.
CAUTION: Care must be taken not to
damage oil seal when removing drive shaft
from gearbox18.Remove and discard circlip from drive shaft.
Refit
1.Inspect gearbox seal for signs of wear or
damage.
2.Wipe drive shaft ends, gearbox oil seal and
hub.
3.Lubricate oil seal running surfaces.
4.Fit new circlip to drive shaft.
5.Fit drive shaft ensuring circlip is fully engaged.
CAUTION: Drive shaft must be fitted with
care to prevent damage to gearbox oil seal.
6.Position drive shaft in hub.
7.Fit new hub nut but do not tighten at this stage.
8.Fit hub to damper, fit nuts and bolts and tighten
to 205 Nm (150 lbf.ft).
9.Position caliper to brake disc fit bolts and
tighten to 100 Nm (74 lbf.ft).
10.Clean ABS sensor and mating face.
11.Lubricate ABS sensor with anti-seize grease.
12.Fit ABS sensor .
CAUTION: Ensure ABS sensor is fully
located into hub, so that sensor touches
reluctor ring.
13.Position ABS harness and brake hose in
bracket and secure with clip.
14.Fit splash shield and secure with bolts.
15.Tighten front hub nut to 400 Nm (295 lbf.ft).
16.Stake front hub nut.
17.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
18.Check and top up oil level as required.

+ MAINTENANCE, MAINTENANCE,
Intermediate Reduction Drive - Non NAS
models.
19.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
20.Remove stands and lower vehicle.
21.Connect battery earth lead.

INTERIOR TRIM COMPONENTS
REPAIRS 76-3-9
Console - front - up to 04MY
$% 76.25.01
Remove
1.Remove rear console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - rear.
2.Remove radio.

+ IN CAR ENTERTAINMENT,
REPAIRS, Radio - up to 04MY.
3.Remove gear lever knob.
4. Manual gearbox only: Remove descent
selector.
5.Remove 3 heater control knobs.
6.Remove 2 screws from heater control panel.
7.Remove heater control panel.8.Release tags and remove radio cage.
9.Remove 2 screws from top of console.
10.Remove 4 screws securing heater controls to
centre console.
11.Remove 3 screws from centre and sides of
console.
12.Disconnect multiplugs and bulb holder from
switch pack.
13. Automatic gearbox only: Disconnect
multiplugs from gear selector.

INTERIOR TRIM COMPONENTS
76-3-10 REPAIRS
14.Remove centre console.
15.Remove 4 screws from switch pack assembly
and remove assembly.Refit
1.Position switch pack assembly, fit and tighten
screws.
2.Position console to fascia.
3.Connect multiplugs and bulb holder to switch
pack.
4. Automatic gearbox only: Connect multiplugs
to gear selector.
5.Fit centre console.
6.Fit and tighten screws securing centre and
sides to console.
7.Fit and tighten screws securing switch pack to
console.
8.Fit and tighten screws to top of console.
9.Position radio cage to console and secure with
retaining tags.
10.Position heater control panel, fit and tighten
screws.
11.Fit heater control knobs.
12. Manual gearbox only: Fit descent selector.
13.Fit gear lever knob.
14.Fit radio.

+ IN CAR ENTERTAINMENT,
REPAIRS, Radio - up to 04MY.
15.Fit rear console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - rear.

INTERIOR TRIM COMPONENTS
REPAIRS 76-3-11
Console assembly - front - from 04MY
$% 76.25.01
Remove
1.Remove rear console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - rear.
2.Remove gear selector indicator assembly.

+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Selector indicator - from 04MY.
3.Carefully lever upper console finisher rearward,
to release clips on forward edge of finisher.
4.Remove 4 screws securing centre console.5.Disconnect 6 multiplugs and remove console.
NOTE: Do not carry out further dismantling if
component is removed for access only.
6.Remove switches from console, noting fitted
position.
7.Remove 4 screws securing ash tray to centre
console finisher and remove ash tray.
Refit
1.Fit switches to console.
2.Fit and secure ash tray to centre console
finisher.
3.Position console assembly and connect
multiplugs.
4.Fit console and secure with screws.
5.Align upper console finisher and secure with
clips.
6.Refit gearshift selector assembly.

+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Selector indicator - from 04MY.
7.Fit rear console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - rear.
M76 4695

PANEL REPAIRS
77-2-30 REPAIRS
Front sidemember (complete)
In this procedure, the front sidemember closing
panel and the related crossmember to sidemember
gusset plate are replaced in conjunction with the front
sidemember.
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove road wheel(s).
5.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
6.Remove front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
7.Remove front bumper armature.
8.Remove radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
9.Remove PAS fluid cooler.

+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
10.Remove headlamp.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
11.Release wiring to headlamp and position aside.
12.Remove engine bay shield.
13.Remove front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
14.Remove front suspension rear beam.
15.Remove engine and gearbox.

+ ENGINE - K SERIES KV6, REPAIRS,
Engine and automatic gearbox - up to 03MY.
16.Remove PAS rack.

+ STEERING, REPAIRS, Power
steering rack.
17.Remove fascia.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia - up to 04MY.
18. LH side: Remove front bumper LH support
bracket.
19. LH side: Remove LH engine mounting from
body.
20. LH side: Remove battery.

+ CHARGING AND STARTING,
REPAIRS, Battery.
21. LH side: Remove air intake hose.
22. LH side: Remove horn.

+ SECURITY, REPAIRS, Horn.
23. RH side: Remove front bumper RH support
bracket.24. RH side: Remove RH engine mounting from
body.
25. RH side: Remove windscreen washer
reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
26. Driver's side: Remove passenger
compartment fuse box.
27. Driver's side: Remove brake pedal box and
brake servo.
28. Driver's side: Remove clutch pedal box.
29.Remove treadplate from front door aperture.
Release front carpet and position aside.
30.Remove insulation pads from engine bulkhead.

PANEL REPAIRS
REPAIRS 77-2-31
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
Refit
1.Fit insulation pads to engine bulkhead.
2.Position front carpet and fit treadplate to front
door aperture. 3. Driver's side: Fit clutch pedal box.
4. Driver's side: Fit brake pedal box and brake
servo.
5. Driver's side: Fit passenger compartment fuse
box.
6. LH side: Fit horn.

+ SECURITY, REPAIRS, Horn.
7. LH side: Fit air intake hose.
8. LH side: Fit battery. Do not connect battery
earth lead.

+ CHARGING AND STARTING,
REPAIRS, Battery.
9. LH side: Fit LH engine mounting to body.
10. LH side: Fit front bumper LH support bracket.
11. RH side: Fit windscreen washer reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
12. RH side: Fit RH engine mounting to body.
13. RH side: Fit front bumper RH support bracket.
14.Fit fascia.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia - up to 04MY.
15.Fit PAS rack.

+ STEERING, REPAIRS, Power
steering rack.
16.Fit engine and gearbox.

+ ENGINE - K SERIES KV6, REPAIRS,
Engine and automatic gearbox - up to 03MY.
17.Fit front suspension rear beam.
18.Fit front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
19.Fit engine bay shield.
20.Fit headlamp.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
21.Secure headlamp wiring.
22.Fit PAS fluid cooler.

+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
23.Fit radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
24.Fit front bumper armature.
25.Fit front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
26.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
27.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
28.Connect all ECUs.
29.Connect alternator.
30.Connect battery earth lead.

PANEL REPAIRS
REPAIRS 77-2-33
Refit
1. LH side: Fit horn.

+ SECURITY, REPAIRS, Horn.
2. LH side: Fit air intake hose.
3. LH side: Fit air cleaner.
4. LH side: Fit battery carrier. Do not connect
battery earth lead.

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
5. LH side: Fit ECM.
6. LH side: Fit front bumper LH support bracket.
7. RH side: Fit PAS pump.

+ STEERING, REPAIRS, Pump -
steering - KV6.
8. RH side: Fit alternator.

+ CHARGING AND STARTING,
REPAIRS, Alternator - KV6.
9. RH side: Fit windscreen washer reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
10. RH side: Fit front bumper RH support bracket.
11.Fit front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
12.Fit engine bay shield.
13.Fit headlamp.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
14. Secure headlamp wiring.
15.Fit PAS fluid cooler.

+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
16.Fit radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
17.Fit front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
18.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
19.Connect all ECUs.
20.Connect battery earth lead.
Front valance assembly
Remove
1.Disconnect battery earth lead.
2.Disconnect all ECUs.
3.Remove road wheel(s).
4.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
5.Remove front bumper valance.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
6.Remove front bumper armature.
7.Remove radiator.

+ COOLING SYSTEM - K SERIES KV6,
REPAIRS, Radiator assembly.
8.Remove PAS fluid cooler.

+ STEERING, REPAIRS, Oil cooler -
Td4 & K1.8 models.
9.Remove headlamp.

+ LIGHTING, REPAIRS, Headlamp
assembly - up to 04MY.
10.Release wiring to headlamp and position aside.
11.Remove engine bay shield.
12.Remove front wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - front wheel arch.
13.Remove front wing.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front.
14.Remove front suspension rear beam.
15.Remove engine and gearbox.

+ ENGINE - K SERIES KV6, REPAIRS,
Engine and automatic gearbox - up to 03MY.
16.Remove front damper.

+ FRONT SUSPENSION, REPAIRS,
Damper.
17.Remove PAS rack.

+ STEERING, REPAIRS, Power
steering rack.
18.Remove fascia.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia - up to 04MY.
19. LH side: Remove front bumper LH support
bracket.
20. LH side: Remove air cleaner.
21. LH side: Remove air intake hose.
22. LH side: Remove ECM.
23. LH side: Remove engine compartment
fusebox.
24. LH side: Remove battery carrier.

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
25. LH side: Remove engine compartment fuse
box and related wiring.

PANEL REPAIRS
77-2-34 REPAIRS
26. LH side: Remove LH engine mounting from
body.
27. LH side: On models with Diesel engines,
remove fuel filter.

+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Filter - main - up to 03MY.
28. LH side: Remove LH front brake pipe.
29. RH side: Remove front bumper RH support
bracket.
30. RH side: Remove windscreen washer
reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
31. RH side: Remove coolant expansion tank.
32. RH side: Remove RH engine mounting from
body.
33. RH side: Remove PAS fluid reservoir.
34. RH side: Remove RH front brake pipe.
35. Driver's side: Remove passenger
compartment fuse box.
36.Remove brake pedal box and brake servo.
37.Remove clutch pedal box.
38.Release vehicle harness from valance and
position aside.
39.Remove treadplate from front door aperture.
Release front carpet and position aside.
40.Remove insulation pads from engine bulkhead.
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown. Refit
1.Fit insulation pads to front and rear sides of
engine bulkhead.
2.Position front carpet and fit treadplate to front
door aperture.
3.Secure vehicle harness to valance.
4. Driver's side: Fit clutch pedal box.
5.Fit brake pedal box and brake servo.
6.Fit passenger compartment fuse box.
7. LH side: Fit LH front brake pipe. Bleed brake
system.
+ BRAKES, ADJUSTMENTS, Brake
bleed.
8. LH side: On models with Diesel engines, fit fuel
filter.

+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Filter - main - up to 03MY.
9. LH side: Fit LH engine mounting to body.
10. LH side: Fit engine compartment fuse box and
related wiring.
11. LH side: Fit battery carrier. Do not connect
battery earth lead.

+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
12. LH side: Fit engine compartment fusebox.
13. LH side: Fit ECM.
14. LH side: Fit air intake hose.
15. LH side: Fit air cleaner.
16. LH side: Fit front bumper LH support bracket.
17. RH side: Fit RH front brake pipe. Bleed brake
system.

+ BRAKES, ADJUSTMENTS, Brake
bleed.
18. RH side: Fit PAS fluid reservoir.
19. RH side: Fit RH engine mounting to body.
20. RH side: Fit coolant expansion tank.
21. RH side: Fit windscreen washer reservoir.

+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
22. RH side: Fit front bumper RH support bracket.
23.Fit fascia.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia - up to 04MY.
24.Fit PAS rack.

+ STEERING, REPAIRS, Power
steering rack.
25.Fit front damper.

+ FRONT SUSPENSION, REPAIRS,
Damper.
26.Fit engine and gearbox.

+ ENGINE - K SERIES KV6, REPAIRS,
Engine and automatic gearbox - up to 03MY.
27.Fit front suspension rear beam.
28.Fit front wing.

+ EXTERIOR FITTINGS, REPAIRS,
Wing - front.