LAND ROVER FRELANDER 2 2006 Repair Manual

from the clut ch pedal .
The main components of t he clut ch are t he clut ch cover as s embly (pres s ure pl ate), the engine flywheel and the drivenplat e (fricti on plate). Toget her wit h fl ywheel and dri ven plate, t he clutch cover forms a fri ct ion s ys tem and is mount ed t ot he fl ywheel by bolt s in the hous ing.
Clutch Cover
ItemPart NumberDescription
1-Cont act plat e2-Di aphragm s pri ng
3-Cover
4-Mount ing holesThe clutch cover ens ures t hat the engine torque i s t rans ferred via the driven plat e t o t he trans mi s si on int ake shaft. Thecont act force requi red for trans ferring engine t orque i s provided by a sl ott ed diaphragm spring. The diaphragm s pri ngall ows the driver to appl y les s pres s ure on the cl ut ch pedal due t o l ow engagi ng force. A contact plat e provides t he frict ions urface for the driven plat e t o engage on.
The diaphragm spring i s of the compres s ed t ype which is act uat ed by t he s lave cyl inder. W hen the s l ave cyli nder i soperated, t he force from t he diaphragm spring i s t ransferred t hrough the cl ut ch cover housi ng int o t he fl ywheel it i s bolt edt o, releas ing t he pres s ure on t he dri ven plate and dis engaging the drive t o t he transmis si on.
The clutch cover contact plat e is att ached t o t he clutch hous ing by pl at e s pri ngs . Cams on the contact plat e projectt hrough the openings i n the hous ing and t he outer di aphragm s prings are s upported on the cams . The cont act pl at e i satt ached t o t he housi ng by bolt s and wire rings . W hen t he s lave cyl inder is operat ed, t he pres s ure on the di aphragms prings i s rel eas ed and t he cont act pl ate can pi vot on the cams , rel eas ing the pres sure on the driven plat e.
Driven Plate

The dri ven pl ate is t he cent ral connecti on element i n the cl utch. In combi nat ion wi th the cl ut ch cover as sembl y, its eparates and l inks engi ne and powert rain by connect ing the engine cranks haft t o t he trans mi s si on input s haft.
The dri ven pl ate is a ri gi d t ype fricti on plat e. The flywheel is of t he dual mas s t ype and abs orbs torque fluct uat ionsgenerated by t he combust ion proces s es to reduce noi s e and wear in t he t rans mis s ion.
Dual Mass Flywheel
The dual mas s flywheel compris es t wo main components ; t he pri mary s i de which i s att ached t o t he engi ne crankshaft andt he secondary s ide t o whi ch the clut ch cover as sembl y is at t ached.
The pri mary si de has the st art er ri ng gear at tached to it s outer circumference. The ring gear is us ed by t he s tarter mot or torot ate the engine during engine crank at s t art up. The primary s ide is s ecured t o t he cranks haft wi th eight bol ts . A dowelin the cranks haft flange ens ures that t he fl ywheel is correctl y located.
The s econdary s ide has the s moot h frict ion s urface on which t he dri ven pl ate fri cti on material engages . Dowel s and fixingholes all ow for the correct al ignment and att achment of the cl utch cover as s embl y.
The pri mary and secondary s ides are connect ed wi th l ong coi l springs . The two si des can rotat e agains t each ot her, li mi tedby t he coi l springs , whi ch absorb t orque loading on cl ut ch engagement and t ors ional vi brati ons from t he engine.

Publi s hed: 11-May-2011
Manual Transmission/Transaxle and Clutch - General Information - Manual
Transaxle and Clutch
Diagnosi s and Tes ti ng
Principles of Operation
For a detail ed descripti on of the manual t rans mis s ion/t rans axl e and clut ch, refer to the relevant Des cri pti on and Operati ons ect ion i n t he works hop manual . REFER to:
Manual Trans mis s ion and Cl utch (308-00 Manual Trans mi s si on/Trans axl e and Clut ch - General Informat ion,Descri pti on and Operat ion),Clutch Cont rols (308-02 Cl utch Controls , Descripti on and Operat ion),Ext ernal Cont rol s (308-06 Manual Trans mi ss ion/Transaxle Ext ernal Cont rol s , Des cri pti on and Operati on),Four-W heel Drive Syst ems (308-07A Four-W heel Drive Sys tems , Des cript ion and Operat ion),Transfer Case (308-07B Trans fer Cas e, Descripti on 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 mechani cal or electrical damage.2.
Visual Inspection
MechanicalElectrical
Trans mi ss ion fl ui d l eaksClut ch fl uid l eaksMi ss i ng fi xi ngsSwit chesShift mechanis ms
W iring harnes s esSwi tches
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 sympt om and refer t o t he Sympt om Chart.4.
Symptom Chart
• NOTE: Check trans mi ss i on fl uid l evel pri or to carrying out any further diagnosi s .REFER to: Trans mi ss i on Fl uid Level Check (308-03 Manual Trans mi ss i on/Trans axl e, General Procedures ).
SymptomPossible CauseActionSignificant effortrequi red whendownshi ft ing ors ynchroni zer cras hing
Gear s hift mechanis mGear s ynchroni zat ion i si nadequate
Check int egrit y of gear s hift mechani sm and for correcti nst all at ion. If gear s ynchroni zat ion i s inadequat e, ins tall a newt rans mis s ion. Refer t o t he new module/component ins tall ati onnot e at the top of t he DTC IndexGear jumps out ofengagement whil edri ving
W orn or broken s ynchroni zercomponent sManufact uring error(incorrect gear wheelt oothi ng or synchronizerring)
Inst all a new transmis si on, refer t o t he new module/componenti nst all at ion not e at t he top of t he DTC Index
Gears hift li nkagedoes not operat efreely (s ti ff orpart ial ly s eized)
Excess ive fricti on in leverbeari ngGearshi ft s elector cabl esas s embly damaged or wornGear s hift mechanis mPos s ible fault i nt rans mi ss i on
Check and ins tal l a new l ever bearing as neces sary. Checki ntegri ty of gears hift cabl es and mechanis m, and for correcti nst all at ion. If internal component s are s us pect , ins t al l a newt rans mis s ion, refer to the new modul e/component i ns t allat ionnot e at the top of t he DTC Index
Brief s cratching nois eduri ng gear s hifti ngInadequate gears ynchroni zat ionInst all a new transmis si on, refer t o t he new module/componenti nst all at ion not e at t he top of t he DTC Index
Leak fromt rans mis s ion hous ingLeak from breatherLeak from fi ll/drai n plugsSeali ng li p of t hei nput /out put shaft oi l seal sdamagedLeak from the s elect or s haftoi l sealLeak from cranks haft rears ealLeak from cl utch hydrauli cs
Check and recti fy flui d leaks from breather, fil l/drain plugs,s eals and clut ch hydraul ics
Cli cki ng nois es inreverse gearGear wheels chippedInst all a new transmis si on, refer t o t he new module/componenti nst all at ion not e at t he top of t he DTC Index

SymptomPossible CauseAction
Gear wheel s bangi ngwhen s hifti ngLow trans mi s si on fl uid l evelCl utch not cleari ngSel ect or forks ors ynchroni zer rings
Check and top-up transmis si on fluid. Check for correct operati onof clut ch. If sel ect or fork or synchronizer rings s us pect , ins tall anew trans mi ss i on, refer t o the new module/componenti nst all at ion not e at t he top of t he DTC Index
Nois es i n t he forwardgearsLow trans mi s si on fl uid l evelThe engine/trans mi s si onas s embly i s in cont act wi tht he chass is /bodyEngine/trans mi s si on fl angebol tsInput and out put shaftbeari ngs
Check top-up transmis si on fluid. Ensure engine/t rans mis s ionas s embly i s not in contact wit h t he chas s is /body. Tightenengine/t rans mi ss i on fl ange bol ts t o correct t orque.REFER t o: Specificati ons (308-00 Manual Transmis s ion/Trans axleand Cl ut ch - General Informat ion, Specificati ons).If input or out put bearings are sus pect , ins t al l a newt rans mis s ion, refer to the new modul e/component i ns t allat ionnot e at the top of t he DTC Index
Gears jump out ofengagementEngine/trans mi s si on s upporti nsul atorGearshi ft l inkagemalfuncti onInternal component s
Repair and i ns t all new engine/t rans mis s ion support i ns ulat or asneces s ary. Check gearshi ft mechani s m i s ins t al led and adjus t edcorrect ly. If internal component s are s us pect , ins t al l a newt rans mis s ion, refer to the new modul e/component i ns t allat ionnot e at the top of t he DTC Index
One of t he gears(parti cul arl y revers e)cannot be s elected
Gearshi ft l inkagemalfuncti onTrans mi s si on int ernals elect ion probl em
Check gears hi ft mechanis m is i ns t alled and adjust ed correct ly.If int ernal components are s uspect, i nst all a new trans mi s si on,refer t o the new module/component i nst all ati on not e at t he t opof t he DTC Index
Unable t o s elect fi rs tand s econd gears(thi rd, s ixth andreverse ok)
Broken sel ect or pi n i n gategui de (i nternal t ot rans mi ss i on shi ftmechanis m)
Inst all new t rans mi ss i on int ernal s hift mechani sm (do noti nst all new t rans mis s ion for thi s faul t)
Gears hift li nkage hasexces s ive playGearshi ft l ever bearing wornGearshi ft s elector cabl esas s embly damaged or worn
Check and ins tal l new gears hi ft l ever beari ng and cabl es asneces s ary
Clut ch s lippi ngCl utch pedal free pl aySt icking clut ch pedalCl utch pres s ure pl ate anddi aphragm s pri ngsCl utch drive plat e frict ionmateri al worn/contami natedFl ywheelSl ave cyli nder s t ickingExcess ive temperat ure
Check cl utch pedal has s uffici ent free pl ay and is not s t icki ng.Check and ins tal l new cl utch pres s ure and drive pl ates asneces s ary. Check integrit y of fl ywheel. Check and ins tal l news lave cyli nder as requi red
Clut ch chat ter ors hudderEngine mount sO il cont aminat ion on drivepl ateDi aphragm s pri ngsCl utch pres s ure pl ateFl ywheel
Check int egrit y of engi ne mounti ngs . Check integrit y and forcontami nat ion of clut ch components . Check condit ion offlywheel. Rect ify and i ns t all new component s as neces s ary
Clut ch drag (diffi cul tys hifti ng)Ins uffi cient brake fl uidAi r in cl ut ch hydraulics ys temCl utch pedal free pl ayIns uffi cient cl utch pedalt ravelDi aphragm s pri ngsDrive pl ate fri cti on materialcontami nati onCl utch dis c s pli nes
Check/top-up brake hydrauli c fl ui d l evel and check clut chhydrauli c s ys t em for leaks . Check cl utch free pl ay and travel .Check int egrit y of clutch, ensure dri ve plate moves freel y on t hei nput s haft s pli nes
Clut ch pedalpuls ati onCl utch and brake pedal pivots haft not correct ly l ubricat edDamaged s pri ngs in press urepl ateRel eas e beari ng nois y orwornFl ywheel
Check for free movement of cl utch pedal at pi vot . Checki ntegri ty of clut ch pres s ure plat e, releas e beari ng and fl ywheel

Publi s hed: 11-May-2011
Manual Transmission/Transaxle and Clutch - General Information - Clutch
System Bleeding
General Procedures
Check that all t he clutch l ine connect ions are ti ght and t hat thereare no s igns of leaks.1.
2.
3. W ARNING: Do not allow dirt or forei gn li qui ds to ent er theres ervoi r. Us e only new brake fl uid of t he correct s peci fi cat ion fromairti ght cont ai ners . Do not mix brands of brake fl uid as t hey may notbe compati ble.
CAUTION: Brake fl ui d wi ll damage paint fi nis hed s urfaces. Ifs pil led, immedi at ely remove t he fl uid and clean t he area wit h wat er.
Remove t he brake fluid res ervoir cap.
3.
Fil l the brake fl ui d res ervoi r to t he MAX mark.4.

At tach t he cl ear bl eed tube t o t he clut ch bl eed s crew
and i mmers e t he free end of t he bleed t ube in a bleed
jar contai ni ng a s mal l quanti ty of approved brake flui d.
5.
Loosen t he bleed s crew by two compl ete turns .
6.
7. CAUTION: The brake flui d res ervoir mus t remain full wi th
new, clean brake fluid at al l ti mes duri ng bleeding.
Depres s t he clutch pedal st eadi ly through i ts full s t roke. W it h t he
pedal held down, clos e t he bleed s crew. W hen the bl eed screw is
ful ly cl os ed, all ow t he cl utch pedal t o return t o the res t pos i ti on.
Repeat t he procedure unt il a flow of cl ean, air-free flui d is bei ng
pumped int o t he bleed jar.
7.
8. CAUTION: Make s ure the bl eed screw cap is i nst all ed aft er
bleeding. This wi ll prevent corros ion t o t he bleed s crew.
W it h the cl utch pedal full y depress ed, ti ght en t he bleed s crew.
T orque: 10 Nm 8.
Fil l the brake fl ui d res ervoi r to t he MAX mark.
9.

Publi s hed: 11-May-2011
Manual Transmission/Transaxle and Clutch - General Information -
Gearshift Cable Adjustment
General Procedures
Check the gears hift operati on.1.
Pos it ion t he gears hi ft l ever i n NEUTRAL.2.
Remove t he gear s elector knob.
Refer t o: Gears hi ft Lever Knob (308-06 ManualTrans mi ss ion/Transaxle Ext ernal Cont rol s , Removal andInst all at ion).
3.
4.
5.

Releas e t he LH cabl e s ecuring cli p.All ow t he gears hift lever t o come t o rest in t heneutral pos it ion.Secure t he cabl e s elect or clip, wi thout dis turbingt he gears hi ft s elect or l ever pos it ion.
6.
Secure t he gear s elector cover.7.
Inst all t he s towage compart ment tray.8.
Inst all t he gear s elector knob.
Refer t o: Gears hi ft Lever Knob (308-06 ManualTrans mi ss ion/Transaxle Ext ernal Cont rol s , Removal andInst all at ion).
9.

Publi s hed: 11-May-2011
Clutch -
Lubricants, Fluids, Sealers and AdhesivesItemSpecification
Recommended hydraul ic fluidSHELL DONAX Y B DOT4 ESL FLUID
General Specification
ItemSpecification
Clut ch make/t ypeLUK - Self adjus ti ng clutchClut ch s ize250 mm (9.84 in)
Clut ch plat e frict ion mat eri alVal eo 810 DS
Mas ter cylinder makeFTESlave cyli nder make/t ypeFTE Concent ric s lave cylinder
Torque Specifications
DescriptionNmlb-ft
Clut ch cover t o fl ywheel bolt s - vehi cles buil t up to 11MY * +2317Clut ch cover t o fl ywheel bolt s - vehi cles buil t 11MY onwards* +2921
* T ighten bolts progressively by diagonal selection.
+ New bolts must be installed.

Publi s hed: 11-May-2011
Clutch - Clutch Disc and Pressure Plate
Removal and Inst all ati on
Special T ool(s) 303-1272
Locki ng Tool , Flywheel 308-667
Al igner, Clut ch
Removal Di sconnect t he bat t ery ground cable.
Refer t o: Specificati ons (414-00 Bat tery and Charging Sys tem -
General Informat ion, Specificati ons).
1.
2. W ARNING: Make sure t o s upport the vehicle wit h axle
s tands .
Rais e and s upport t he vehi cl e.
2.
Remove t he transmis si on as sembl y.
Refer t o: Transmis s ion (308-03 Manual Trans mi s si on/Trans axl e,
Removal).
3. Speci al Tool (s ):
303-1272 4.