ird LAND ROVER FREELANDER 2001 Repair Manual

INTERMEDIATE REDUCTION DRIVE
REPAIRS 41-29
14.Remove 2 remaining nuts securing pinion
housing.
15.Remove pinion housing.
16.Remove and discard 'O' ring.
17.Remove and retain spacing washer.Refit
1.Clean pinion housing and mating face on IRD
casing.
2.Clean spacing washer.
3.Fit spacing washer to IRD.
4.Lubricate new 'O' ring with IRD fluid and fit to
groove in pinion housing.
5.Fit pinion housing.
6.Fit exhaust heat shield and fit nuts finger tight.
7.Fit manifold heat shield and fit nut securing
heat shield to pinion housing finger tight.
8.Fit nut securing heat shield to IRD and tighten
to 45 Nm (33 lbf.ft).
9.Fit bolts securing manifold heat shield to IRD
support bracket and tighten to 9 Nm (7 lbf.ft).
10.Fit remaining nuts securing pinion housing and
tighten all nuts to 25 Nm (18 lbf.ft).
11.Tighten nut securing exhaust heat shield to
exhaust mounting bracket to 45 Nm (33 lbf.ft).
12.Ensure mating face of propeller shaft and IRD
drive flange are clean.
13.Fit propeller shaft to IRD flange and align
marks. Tighten nuts and bolts to 40 Nm (30
lbf.ft).
14.Fill IRD to correct level with fluid.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
Non NAS.
15.Lower axle and remove jack.
16.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
17.Remove stands and lower vehicle.

INTERMEDIATE REDUCTION DRIVE
41-30 REPAIRS
Seal - pinion gear housing - KV6 - NAS
$% 41.29.11
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
3.Remove front exhaust pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Front pipe - NAS.
4.Drain fluid from IRD.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) lubrication system -
drain & refill - NAS.
5.Raise one rear wheel for rotation of propeller
shaft to access bolts.
6.Reference mark front propeller shaft for
reassembly.
7.Remove 6 nuts and bolts securing propeller
shaft to IRD drive flange.
8.Release propeller shaft from IRD drive flange
and tie shaft aside.
CAUTION: Care must be taken to support
the Tripode joint when removed from the
IRD unit. To avoid damage to gaiter or steel
can, the joint should not be allowed to fully
extend or be dropped.
9.Remove 2 nuts from pinion housing securing
front exhaust pipe bracket, remove bracket.
10.Remove nut securing heat shield to IRD unit,
remove shield.11.Remove 2 remaining nuts securing pinion
housing.
12.Remove pinion housing.
13.Remove and discard 'O' ring.
14.Remove and retain spacing washer.

INTERMEDIATE REDUCTION DRIVE
REPAIRS 41-31
Refit
1.Clean pinion housing and mating face on IRD
casing.
2.Clean spacing washer.
3.Fit spacing washer to IRD.
4.Lubricate new 'O' ring with IRD fluid and fit to
groove in pinion housing.
5.Fit pinion housing.
6.Fit exhaust bracket and heat shield, secure with
nuts and tighten to 10 Nm (7 lbf.ft).
7.Fit nut securing heat shield to IRD and tighten
to 45 Nm (33 lbf.ft).
8.Fit remaining nuts securing pinion housing and
tighten all nuts to 25 Nm.
9.Ensure mating face of propeller shaft and IRD
drive flange are clean.
10.Fit propeller shaft to IRD flange and align
marks. Tighten nuts and bolts to 42 Nm (31
lbf.ft).
11.Fit front exhaust pipe.

+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Front pipe - NAS.
12.Lower axle and remove jack.
13.Fill IRD to correct level with fluid.

+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) lubrication system -
drain & refill - NAS.
14.Fit underbelly panel.

+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
15.Remove stands and lower vehicle.

AUTOMATIC GEARBOX - JATCO
44-12 REPAIRS
Gearbox - KV6 - with engine and gearbox
removed
$% 44.20.01.99
Remove
1.Release HO2S multiplug from support bracket
on LH camshaft cover, disconnect multiplug.
2.Remove 4 nuts securing LH exhaust manifold
to cylinder head.
3.Remove exhaust manifold, remove and discard
gasket.4.Remove nut securing manifold heat shield to
IRD unit.
5.Remove nut securing heat shield to IRD pinion
housing.
6.Remove 2 bolts securing heat shield and
remove heat shield.
7.Disconnect breather hose from IRD housing.
8.Release clips and disconnect coolant hoses
from IRD.

AUTOMATIC GEARBOX - JATCO
REPAIRS 44-13
9.Remove bolt securing engine lower steady to
IRD support bracket.
10.Remove lower engine steady noting that 'TOP'
mark on engine steady faces uppermost.
11.Remove 3 bolts securing IRD support bracket
to sump.
12.Remove 2 bolts securing IRD support bracket
to engine front mounting plate.13.Remove 5 bolts securing support bracket to
IRD.
14.Remove support bracket.
15.Remove 4 bolts securing IRD.
16.With assistance, release IRD from gearbox and
remove.
17.Remove and discard 'O' ring from IRD.
M41 7698

AUTOMATIC GEARBOX - JATCO
44-14 REPAIRS
18.Remove 2 bolts securing torque converter
access plate.
19.Remove access plate.
20.Mark drive plate to torque converter, for refit
purposes.
21.Remove 4 bolts securing drive plate to
converter.
22.Remove bolt securing IRD cooling hose
retainer. Remove retainer.23.Remove bolts securing LRT-44-026 lifting
bracket to gearbox and remove bracket.
24.Remove 3 bolts securing starter motor to
gearbox noting that the LH bolt also secures
the mounting bracket for the CKP sensor
multiplug.
25.Remove starter motor.
M44 1661
M44 1649

AUTOMATIC GEARBOX - JATCO
44-16 REPAIRS
35.Remove 2 top bolts securing gearbox to
engine.
36.Release gearbox from 2 dowels.
37.Remove gearbox assembly.
38.Fit converter retaining plate and secure with
bolts.Refit
1.Remove torque converter retaining plate.
2.Ensure converter is fully located in oil pump
drive by checking depth 'A' as illustrated. Depth
A = 4 mm.
3.Clean gearbox to engine mating faces, dowels
and dowel holes.
4.Fit gearbox assembly.
5.Fit bolts securing gearbox and tighten to 85 Nm
(63 lbf.ft).
6.Disconnect lifting equipment.
7.Clean CKP sensor and mating face.
8.Fit CKP sensor, fit bolt and tighten to 9 Nm (7
lbf.ft).
9.Position fluid cooler, tighten M12 bolts to 85 Nm
(63 lbf.ft) and M8 bolt to 25 Nm (18 lbf.ft).
10.Connect hoses to fluid cooler.
11.Clean fluid cooler unions.
12.Lubricate new 'O' rings with clean transmission
fluid and fit 'O' rings to fluid cooler hoses.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
13.Connect fluid cooler hoses to gearbox and
tighten unions to 18 Nm (13 lbf.ft).
14.Clean starter motor mating faces.
15.Position starter motor to gearbox, align CKP
sensor multiplug bracket, fit and tighten bolts to
45 Nm (33 lbf.ft).
16.Using gearbox bracket bolts, secure LRT-44-
026 lifting bracket to gearbox.
17.Position IRD cooling hose retainer, fit bolt and
tighten to 25 Nm (18 lbf.ft).
18.Align marks on drive plate to torque converter.
19.Fit bolts securing drive plate to torque converter
and tighten bolts to 45 Nm (33 lbf.ft).
20.Clean torque converter access plate.
M44 1689
A
M44 1668

AUTOMATIC GEARBOX - JATCO
REPAIRS 44-17
21.Position access plate, fit bolts and tighten to 9
Nm (7 lbf.ft).
22.Clean mating faces of IRD and gearbox.
23.Lubricate and fit new 'O' ring.
24.With assistance, fit IRD.
25.Fit bolts securing IRD to gearbox and tighten
sufficiently only to pull mating faces of IRD and
gearbox together at this stage.
26.Fit IRD support bracket and tighten bolts
sufficiently only to pull mating faces together.
27.Final tighten bolts securing IRD to gearbox to
80 Nm (59 lbf.ft).
28.Final tighten bolts securing IRD support
bracket in following sequence:5 bolts securing
support bracket to IRD 50 Nm (37 lbf.ft), 2 bolts
securing support bracket to engine front
mounting bracket 50 Nm (37 lbf.ft), 3 bolts
securing support bracket to sump 45 Nm (33
lbf.ft).
29.Position lower engine steady, 'TOP' mark
uppermost. Fit bolt but do not tighten at this
stage.
30.Connect coolant hoses and secure with clips.
31.Connect breather hose to IRD housing.
32.Fit manifold heat shield and fit nut securing
heat shield to pinion housing finger tight.
33.Fit bolts securing manifold heat shield to IRD
support bracket and tighten to 9 Nm (7 lbf.ft).
34.Fit nut securing heat shield to IRD and tighten
to 45 Nm (33 lbf.ft).
35.Final tighten nut securing manifold heat shield
to IRD pinion housing to 25 Nm (18 lbf.ft).
36.Clean exhaust manifold and mating face on
cylinder head.
37.Fit exhaust manifold gasket.
38.Position exhaust manifold, fit nuts and
progressively tighten, from centre outwards to
45 Nm (33 lbf.ft).
39.Connect HO2S multiplug and secure to support
bracket.
Gearbox - KV6
$% 44.20.02.99
Remove
1.Tie bonnet back in upright position.
2.Disconnect battery earth lead.
3.Remove engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
4.Remove IRD.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Intermediate reduction
drive (IRD) unit - KV6.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Intermediate reduction
drive (IRD) unit - KV6.
5.Loosen selector cable trunnion nut.
6.Release clip securing selector cable to gearbox
bracket, remove selector cable and collect
trunnion from selector lever.
7.Remove 3 screws securing LH splash shield
and remove shield.

AUTOMATIC GEARBOX - JATCO
44-18 REPAIRS
8.Secure LRT-54-026 to drive shaft inboard joint.
Using a suitable lever, release inboard joint
from gearbox.
9.With assistance pull hub outwards and release
drive shaft from gearbox.
CAUTION: Care must be taken not to
damage oil seal when removing drive shaft
from gearbox
10.Remove and discard circlip from drive shaft.11.Remove 2 bolts securing torque converter
access plate.
12.Remove access plate.
13.Mark drive plate to torque converter, for refit
purposes.
14.Remove 4 bolts securing drive plate to
converter.
15.Remove bolt securing IRD cooling hose
retainer. Remove retainer.
M44 1661
M44 1649

AUTOMATIC GEARBOX - JATCO
REPAIRS 44-23
23.Fit CKP sensor, fit bolt and tighten to 9 Nm (7
lbf.ft).
24.Position fluid cooler, tighten M12 bolts to 85 Nm
(63 lbf.ft) and M8 bolt to 25 Nm (18 lbf.ft).
25.Clean fluid cooler unions.
26.Lubricate new 'O' rings with clean transmission
fluid and fit 'O' rings to fluid cooler hoses.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
27.Connect fluid cooler hoses to gearbox and
tighten unions to 18 Nm (13 lbf.ft).
28.Clean exhaust manifold and mating face on
cylinder head.
29.Fit exhaust manifold gasket.
30.Position exhaust manifold, fit nuts and
progressively tighten, from centre outwards to
45 Nm (33 lbf.ft).
31.Connect HO2S multiplug and secure to support
bracket.
32.Position IRD cooling hose retainer, fit bolt and
tighten to 25 Nm (18 lbf.ft).
33.Align marks on drive plate to torque converter.
34.Fit bolts securing drive plate to torque converter
and tighten bolts to 45 Nm (33 lbf.ft).
35.Clean torque converter access plate.
36.Position access plate, fit bolts and tighten to 9
Nm (7 lbf.ft).
37.Clean end of drive shaft and mating splines in
gearbox.
38.Fit new circlip to LH drive shaft.
39.With assistance pull hub outwards, align drive
shaft and fit to gearbox, taking care not to
damage drive shaft oil seal.
CAUTION: Pull the drive shaft to ensure the
circlip is fully engaged and retains the shaft.
40.Fit splash shield and secure with bolts.
41.Position trunnion to selector lever, locate inner
cable through trunnion, do not tighten nut at this
stage.
42.Position selector cable to gearbox bracket and
secure with clip.
43.Adjust selector cable.

+ AUTOMATIC GEARBOX - JATCO,
ADJUSTMENTS, Selector cable - adjust.
44.Fit IRD.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Intermediate reduction
drive (IRD) unit - KV6.
45.Connect battery earth lead.
46.Fit engine acoustic cover.

+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
47.Untie and close bonnet.
Gearbox - Td4
$% 44.20.02.99
Remove
1.Disconnect battery earth lead.
2.Tie bonnet back in upright position.
3.Remove intake ducting assembly.

+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Ducting - intake assembly.
4.Remove fluid cooler.

+ AUTOMATIC GEARBOX - JATCO,
REPAIRS, Fluid cooler - Td4.
5.Remove starter motor.

+ CHARGING AND STARTING,
REPAIRS, Starter motor - Td4.
6.Remove IRD.

+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Intermediate reduction
drive (IRD) unit - Td4.
7.Secure LRT-54-026 to drive shaft inboard joint.
Using a suitable lever, release inboard joint
from gearbox.
8.With assistance, pull hub outwards and remove
LH drive shaft from gearbox.
CAUTION: Pull the drive shaft horizontally
to avoid damaging the differential oil seal.