LAND ROVER FRELANDER 2 2006 Repair Manual

Publi s hed: 11-May-2011
Manual Transmission/Transaxle and Clutch - General Information - Manual
Transmission and Clutch
Des cript ion and Operat ion
COMPONENT LOCATION
ItemPart NumberDescription1-Selector lever
2-Manual t rans mi ss ion
OVERVIEW
The M66EHA50 manual t rans mis s ion i s a 6 speed unit manufact ured by Get rag-Ford in Col ogne, Germany. The t rans mis s ionis a highly compact 4 s haft desi gn, incorporati ng t he front final dri ve gear, and is adapted for All W heel Dri ve (AW D) byprovidi ng a connecti on from t he final drive carrier t o t he Power Transfer Uni t. The t rans mi ss i on is capabl e of t ransferringhigh t orque from the engi ne.
The t ransmis s ion feat ures t wo mechanical s hift cabl es from t he s elector l ever and an electronic reverse inhibit or.
The M66EH50 manual t rans mis s ion has t he fol lowi ng feat ures:
380 Nm torque capaci ty (wi th torque truncati on in 1st and revers e gears )Dry weight 61 kgTrans mis s ion oi l is fil l for li fe - 1.9L fill t o l evel plug Oi l s pec MTF97309Front different ial int egral wit h t rans mis s ion6 forward gears4th to 6t h gears and revers e gear have s i ngl e cone synchronizati on3rd gear i s doubl e cone synchronized1s t and 2nd gears have triple cone s ynchroni zat ion.
The clutch s ys tem used is a convent ional s ingle driven plat e and a di aphragm s pri ng cl utch cover as s embly. The cl utch i shydraulicall y operated by operat ion of t he clut ch pedal which di sengages the drive from the engine cranks haft t o t het ransmis s ion.
TRANSMISSION
For shi ft cabl e and s elector l ever descripti on refer to Ext ernal Cont rol s.For addit ional informat ion, refer t o: Ext ernal Control s (308-06 Manual Trans mi ss i on/Trans axl e External Controls ,Des cript ion and Operat ion).

ItemPart NumberDescription
1-Cabl e retaini ng bracket2-Longi tudinal lever
3-1st gear detecti on s wit ch
4-Reverse s wit ch5-Lat eral l ever
6-Shift cable bal l end
7-Trans mis s ion oi l level /fil ler plug8-Trans mis s ion drain pl ug
9-Trans mis s ion cas ing
10-Hydraulic cl utch bleed adaptor11-Input s haft
12-Clut ch sl ave cyl inder
13-Clut ch hous ing14-Different ial output (Right Hand (RH) s ide)
Neutral Gear Sensor - St op/Start Vehi cl es - From 2010 MY
ItemPart NumberDescription1-Neut ral gear s ens or

Neutral Gear Sensor
A PLCD (Permanent Magnet Linear Contactl es s Di s pl acement ) s ens or is i ntroduced on Stop/Start vehi cl es and located ont he ext eri or of t he t rans mis s ion cas ing and hardwi red t o t he ECM. The s ens or’s functi on is to det ect t hat neut ral gear hasbeen s el ect ed wi thin a calibrated wi ndow.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).
Shift Cont rol Mechani sm
ItemPart NumberDescription
1-Shi ft control mechanis m
2-Ball li mit er 5th - 6t h gear cont rol3-Gears hift gat e
4-Flange
5-Gear s hift gate pi n6-Lower gear s el ect or
7-Gear s elect or rod
8-Upper gear s el ect or9-Spring
10-Longit udinal lever
11-Spring12-Lat eral lever
13-Catch plat e
14-Carrier plate15-Bleed cap

16-Ball li mit er for gear sel ect or
The t ransmis s ion i s operated by two shi ft cabl es which are att ached t o t he s elector lever. Movement of the s elect or l everis pas s ed via t he cables t o t wo lever mechanis ms on the top of t he t ransmis s ion. The levers operat e a s hift cont rolmechani sm wi thin the trans mi ss i on to sel ect t he reques ted gear rat io.
The s hift control mechanis m is locat ed at t he front of t he t rans mis s ion and t rans fers the shi ft cable movement int o gears elect ions .
The s hift control mechanis m is a one-piece as sembl y which i s ret ained i n the trans mis si on hous i ng wit h 4 bol ts . The s hi ftcont rol mechani s m moves t he upper and l ower gear s elect or forks vi a t he lat eral and longit udi nal l evers on t he t op of thes hift control mechanis m. There are 2 upper s elector forks and 2 l ower s elector forks as fol lows :
The 2 upper gear s elector forks are us ed t o engage revers e, 1st or 2nd gearsThe 2 l ower gear s elect or forks are us ed t o engage 3rd, 4th, 5th and 6th gears .
The 4 s elector forks t rans fer movement from t he s hi ft control mechanis m to the relevant shi ft coupl ing s leeve. The shi ftforks are mount ed in bearings in the trans mi ss i on cas e.
Two carrier plat es trans fer torque from t he longit udi nal l ever t o t he s lidi ng gear selectors . The carriers are locat ed and runin a groove i n the gear s elector plat e.
The carri er plates can move verti call y between 4 pos i ti ons . The different gears are s elected from one of t he 4 posi ti ons asfol lows :
Uppermos t posi ti on - gear s elect or s elects revers e gearSecond uppermos t posi ti on - gear sel ect or sel ect s 1st and 2nd gearsSecond l owes t pos it ion - gear s el ect or s el ect s 5t h and 6th gearsLowes t pos it ion - gear s el ect or s el ect s 3rd and 4th gears.
The s hift control mechanis m has two s prings t hat return t he s el ect or lever to the neutral pos it ion.
Trans mis s ion Shi ft Selector Shaft s
The above ill ust rat ion s hows t he coupl ing s leeves for each gear clus t er. Movement of t hes e sl eeves as s elected by thes hift control mechanis m, connect t he required gear t rai ns toget her t o produce t he required out put rat io.
The coupl ing s leeve is part of the synchronizing hub as s embly whi ch al s o cons is t s of a flange and the hub. Eachs ynchronizi ng hub is joined t o it s s haft by s pli nes and rot at es wi th it . Idler wheels are fit ted on bot h s ides of eachs ynchronizi ng hub. The i dl er wheel s rot ate freel y on t he s haft (wit h the excepti on of revers e gear). Each i dler wheel i scons t ant ly engaged in it s pinion. The s ynchronizi ng s et i s pos it ioned bet ween t he s ynchronizing hub and the i dler wheel .
The s ynchronizi ng uni ts are pos it ioned on t he s hafts in t he t rans mis s ion as foll ows:
The s ynchronizi ng uni t for 1s t - 2nd gear i s on t he int ermedi at e s haft 1s t - 2nd, 5th - 6t hThe s ynchronizi ng uni t for 3rd - 4th gear i s on t he int ermediat e s haft 3rd - 4thThe s ynchronizi ng uni t for 5t h-6th gear i s on t he input s haftThe s ynchronizi ng uni t for reverse gear i s on t he revers e s haft .
The s ynchronizi ng ri ngs expand when heated by t he s ame amount as t he components they are in contact wit h. As a resul t

no s afet y margi n is required to counter expans i on. The i dl er wheel s for s ingl e and doubl e s ynchronizat ion have no cones .An i nner ring on t he s ynchroni zer unit performs thi s functi on ins tead.
Transmission Gear Cluster
ItemPart NumberDescriptionA-Input s haft
B-Int ermedi at e s haft 1s t t o 2nd, 5t h t o 6th
C-Int ermedi at e s haft 3rd t o 4thD-Reverse s haft
1-Reverse fi nal gear
2-Reverse idler gear3-Reverse gear coupl ing s l eeve
4-Final gear - Di fferenti al
5-2nd gear - i dle gear6-5th gear
7-6th gear
8-6th gear - i dl e gear9-5th to 6t h gear coupli ng s leeve
10-4th gear - i dl e gear
11-5th gear - i dl e gear12-3rd to 4t h gear coupli ng s leeve
13-4th gear
14-2nd gear pat h15-1st gear path
16-3rd gear - i dl e gear
17-3rd to 4t h final gear pini on18-3rd gear
19-1st to 2nd gear coupl ing s leeve
20-1st to 2nd and 5t h t o 6t h fi nal gear pinion21-1st gear - i dl e gear
The gear wheels are l ocat ed on four s haft s, as foll ows:
Input s haftInt ermedi at e s haft 1-2, 5-6Int ermedi at e s haft 3-4Revers e s haft.
In order to keep the s haft s s hort , the clut ch gears are welded direct ly to t he i dl er wheel and needle beari ngs wit h innerri ngs are us ed i ns t ead of snap rings . The inner ri ngs s i t on the shaft ins ide t he idl er gears and ext end lengthwi se out s ideeach idler gear. W hen the component s on t he s hafts are pull ed t oget her t he i nner rings count erhold, s o t hat t he idl erwheels have t he cl earance that t hey requi re to rot at e. The components of t he i nput shaft s are pul led t oget her wit h a boltlocated i n t he end of the shaft . Component s of int ermediat e s haft 3rd -4t h are hel d t oget her wit h a pres s joint and a bol tlocated i n t he end of the shaft . The component s of intermediat e s haft 1st -2nd, 5t h -6th are held together wi th the pres s

joi nt of t he 5t h and 6th gear pini on.
1st Gear Power Flow
ItemPart NumberDescription
A-Input s haftB-Int ermediat e s haft 1s t - 2nd and 5th - 6t h
4-Ring gear
15-1s t gear19-1s t - 2nd gear coupli ng s leeve
20-Fi nal drive 1s t - 2nd and 5th - 6th
21-1s t gear idler gearW hen 1s t gear is s elected, t he coupli ng s leeve for 1s t - 2nd gear i s moved by a gear s elect or fork along t he s ynchronizi nghub t owards the 1s t gear idler gear. The coupl ing s l eeve and t he s ynchroni zi ng hub lock t he 1st gear idl er gear at theint ermediat e s haft 1s t - 2nd and 5th - 6th.
Engi ne t orque is trans ferred to the i nput s haft via the cl ut ch. The 1s t gear rack on t he input s haft transfers t he power tot he 1st gear idl er gear. From t here t he power is t rans ferred t o t he int ermediat e s haft 1s t - 2nd and 5th - 6th and to t hefi nal drive, which i n turn t rans fers power t o t he ri ng gear. The ring gear is connect ed to the drive s haft s t hrough thedifferent ial.
2nd Gear Power Flow
ItemPart NumberDescriptionA-Input s haft
B-Int ermediat e s haft 1s t - 2nd and 5th - 6t h
4-Ring gear5-2nd gear i dl er gear
14-2nd gear
19-1s t - 2nd gear coupli ng s leeve

20-Fi nal drive 1s t - 2nd and 5th - 6th
W hen 2nd gear is sel ect ed, t he coupl ing s leeve for 1s t - 2nd gear is moved by a gear s elector fork al ong the s ynchroni zi nghub t owards the 2nd gear i dl er gear. The coupli ng s leeve and the s ynchroni zing hub lock t he 2nd gear idler gear at theint ermediat e s haft 1s t - 2nd and 5th - 6th.
Engi ne t orque is trans ferred to the i nput s haft via the cl ut ch. The 2nd gear rack on t he i nput s haft t rans fers the power t ot he 2nd gear i dl er gear. From there the power is trans ferred to the i ntermedi ate shaft 1s t - 2nd and 5t h - 6t h and to thefi nal drive, which i n turn t rans fers power t o t he ri ng gear. The ring gear is connect ed to the drive s haft s t hrough thedifferent ial.
3rd G ear Power Flow
ItemPart NumberDescription
A-Input s haft
C-Int ermediat e s haft 3rd - 4th4-Ring gear
12-3rd - 4t h gear coupli ng s leeve
16-3rd gear idl er gear17-Final drive 3rd - 4t h
18-3rd gear
W hen 3rd gear is s elected, t he coupli ng s leeve for 3rd - 4th gear i s moved by a gear sel ect or fork along t he synchronizinghub t owards the 3rd gear idler gear. The coupl ing s l eeve and t he s ynchroni zi ng hub lock t he 3rd gear idl er gear at theint ermediat e s haft 3rd - 4th.
Engi ne t orque is trans ferred to the i nput s haft via the cl ut ch. The 3rd gear rack on t he input s haft transfers t he power tot he 3rd gear idl er gear. From t here t he power is t rans ferred t o t he int ermediat e s haft 3rd - 4th and to the final dri ve, whi chin turn t ransfers power t o t he ri ng gear. The ri ng gear i s connected to t he drive s haft s through the di fferenti al .
4th G ear Power Flow
ItemPart NumberDescription

A-Input s haft
C-Int ermediat e s haft 3rd - 4th
4-Ring gear10-4th gear idl er gear
12-3rd - 4t h gear coupli ng s leeve
13-4th gear17-Final drive 3rd - 4t h
W hen 4t h gear is s elected, t he coupli ng s leeve for 3rd - 4th gear i s moved by a gear s el ect or fork along t he s ynchronizinghub t owards the 4t h gear idl er gear. The coupling sl eeve and t he s ynchroni zi ng hub lock t he 4th gear i dl er gear at t heint ermediat e s haft 3rd - 4th.
Engi ne t orque is trans ferred to the i nput s haft via the cl ut ch. The 4t h gear rack on t he input s haft t ransfers the power tot he 4th gear idl er gear. From t here t he power is t rans ferred t o t he int ermedi at e s haft 3rd - 4th and to the final dri ve, whi chin turn t ransfers power t o t he ri ng gear. The ri ng gear i s connected to t he drive s haft s through the di fferenti al .
5th G ear Power Flow
ItemPart NumberDescriptionA-Input s haft
B-Int ermediat e s haft 1s t - 2nd and 5th - 6t h
4-Ring gear6-5t h gear
9-5t h - 6t h gear coupli ng s leeve
11-5t h gear idl er gear20-Fi nal drive 1s t - 2nd and 5th - 6th
W hen 5t h gear is s elected, t he coupli ng s leeve for 5t h - 6th gear i s moved by a gear s el ect or fork along t he s ynchronizinghub t owards the 5t h gear idl er gear. The coupling sl eeve and t he s ynchroni zi ng hub lock t he 5th gear i dl er gear at t heinput s haft.
Engi ne t orque is trans ferred to the i nput s haft via the cl ut ch. The 5t h - 6t h coupl ing s leeve and 5t h gear i dler gear l ocat edon t he input s haft, t rans fer t he power to t he 5t h gear. From there the power i s transferred to the intermediate s haft 1st -2nd and 5th - 6th and to t he final drive, which i n t urn t rans fers power to t he ring gear. The ring gear is connect ed t o thedri ve s hafts through t he different ial .
6th G ear Power Flow

ItemPart NumberDescription
A-Input s haftB-Int ermediat e s haft 1s t - 2nd and 5th - 6t h
4-Ring gear
7-6t h gear8-6t h gear idl er gear
9-5t h - 6t h gear coupli ng s leeve
20-Fi nal drive 1s t - 2nd and 5th - 6thW hen 6t h gear is s elected, t he coupli ng s leeve for 5t h - 6th gear i s moved by a gear s el ect or fork along t he s ynchronizinghub t owards the 6t h gear idl er gear. The coupling sl eeve and t he s ynchroni zi ng hub lock t he 6th gear i dl er gear at t heinput s haft.
Engi ne t orque is trans ferred to the i nput s haft via the cl ut ch. The 5t h - 6t h coupl ing s leeve and 6t h gear i dler gear l ocat edon t he input s haft, t rans fer t he power to t he 6t h gear. From there the power i s transferred to the intermediate s haft 1st -2nd and 5th - 6th and to t he final drive, which i n t urn t rans fers power to t he ring gear. The ring gear is connect ed t o thedri ve s hafts through t he different ial .
Reverse G ear Power Flow
ItemPart NumberDescriptionA-Input s haft
B-Int ermediat e s haft 1s t - 2nd and 5th - 6t h
D-Revers e shaft1-Fi nal drive for revers e gear
2-Revers e gear idl er gear
3-Revers e gear coupl ing s leeve4-Ring gear
15-1s t gear
21-1s t gear idler gearW hen revers e gear i s s elected, the coupli ng sl eeve for revers e gear is moved by a gear sel ect or fork al ong the

s ynchronizi ng hub towards the revers e gear i dler gear.
The coupl ing s leeve and s ynchronizi ng hub lock t he revers e gear idler gear at the revers e s haft.
The t orque of the engine is t rans ferred via the cl ut ch t o the input shaft. The 1s t gear on t he i nput s haft t rans fers power t ot he 1st gear idl er gear. The power is then t rans ferred t o t he revers e gear idl er gear and then t o t he reverse gear coupl ings leeve. From t here power is trans ferred to t he i nt ermedi ate s haft 1s t - 2nd and 5t h - 6th and to the final dri ve which i nt urn t rans fers power t o t he ring gear. The ring gear is connect ed to the drive s hafts t hrough the di fferenti al.
Differential
The different ial dis t ribut es dri ve from t he t ransmis s ion equally bet ween t he LH and RH front half s haft s and als o provi desdri ve torque to the rear di fferenti al vi a t he power t rans fer unit .
The different ial is locat ed at t he rear of the trans mi ss i on hous ing. Both s ides of the di fferenti al are connected to t he LHand RH drive s haft s, s upplying t orque t o t he front wheel s The different ial is als o connected t o t he Power Transfer Unit viaa s pli ned shaft to the RH s ide of t he trans mi s si on, s upplying t orque t o t he rear driveline.
Reverse Switch
The revers e s wi tch i s located i n t he front of the t rans mis s ion cas ing, above t he 1s t gear det ect ion s wi tch. The swi tch i sus ed by the Ant i-lock Brake Sys tem (ABS) module for Hil l Descent Cont rol (HDC) and als o for revers ing l amp operati on.
1st Gear Position Switch
The 1s t gear s wit ch is locat ed on t he front of the t rans mi ss ion cas ing, below t he reverse swit ch. The s wit ch is us ed by t heABS module for HDC.
CLUTCH
ItemPart NumberDescription1-Clutch pedal
2-Brake/clut ch res ervoir
3-Fl uid l evel s ensor4-Connector
5-Low pres s ure hos e
6-Mast er cyl inder7-High pres s ure cl utch l ine
8-Connector
9-Clutch bl eed adapt or10-Transmis s ion
11-Slave cyl inder and releas e beari ng
12-Clutch cover as s embly13-Dri ven (fri ct ion) plat e
The clutch i s a convent ional si ngl e driven plat e and diaphragm spring clut ch cover ass embly which is hydraul ically act uat ed