LAND ROVER FRELANDER 2 2006 Repair Manual

10.
Releas e t he cabl e s eal ing pl at e.11.
12.

13.
14.
15.
NOTE: Thi s s tep requires the ai d of anot her
t echnician.
Remove t he gears hi ft cable as s embly.
15.
Installation 1. NOTE: Thi s s tep requires the ai d of anot her techni ci an.
Inst all t he gears hi ft cable as s embly.
1.
Inst all t he gears hi ft l ever.
T orque: 10 Nm 2.
Secure t he cabl es in t he cli ps.
3.
Inst all t he heat s hiel d.
4.
Secure t he s el ect or cabl es .
5.

Inst all t he s eal ing plat e.
T orque: 7 Nm 6.
Connect t he s el ect or cabl e ball joi nt s .
7.
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 he
neutral pos it ion. Secure t he cabl e s elect or clip, wi thout dis turbing
t he gears hi ft s elect or l ever pos it ion. 8.
Inst all t he ins trument pack bracket.
T orque: 25 Nm 9.
Secure t he drain tube and heater duct.
10.
Inst all t he ins trument panel, l ower trim panel s.
11.
Inst all t he air cleaner as s embly.
Refer t o: Air Cleaner (303-12A Intake Ai r Dis tribut ion and Fil tering -
I6 3.2L Pet rol, Removal and Ins t al lat ion).
12.
Inst all t he fl oor consol e.
Refer t o: Fl oor Cons ole (501-12 Inst rument Panel and Cons ole,
Removal and Ins tall ati on).
13.
Inst all t he dri ves haft .
Refer t o: Dri ves haft - Vehicles W it hout : Dies el Part icul ate Fi lt er (DPF) (205-01 Driveshaft, Removal and Ins tal lati on).
14.

Publi s hed: 11-May-2011
Four-Wheel Drive Systems - Four-Wheel Drive Systems
Des cript ion and Operat ion
COMPONENT LOCATION
• NOTE: Manual t rans mi ss ion shown, automat ic t rans mis s ion si mil ar.
ItemPart NumberDescription1-Trans mis s ion
2-Power Trans fer Uni t
OVERVIEW
The power trans fer unit is l ocat ed at the rear of t he engine and i s att ached di rectly to the trans mi ss i on cas ing and to theengi ne cyl inder block via a bracket . The power t rans fer unit i s a common unit bet ween the pet rol and dies el engi nevariant s and als o aut omat ic and manual t rans mis s ions .

ItemPart NumberDescription
1-Breather t ube2-Heat s hiel d
3-Engi ne mounti ng bracket
4-Right Hand (RH) half s haft s eal5-Dri ve shaft mount ing fl ange
6-Transmis s ion different ial i nput s haft s pli ne
The power trans fer unit is driven direct ly from t he trans mi s si on different ial via a hol low shaft through whi ch the RH halfs haft pass es . (The Left Hand (LH) half s haft is driven di rectl y from t he t rans mis s ion di fferenti al ). Drive i s t aken t o t hedri ve s haft via a low-offs et hypoi d bevel gear, configured for mi nimal power los s across the s peed range. The powert ransfer uni t t ransfers drive from t he trans mi s si on different ial t o the drive s haft and rear di fferenti al, no drive from thepower trans fer unit is pas sed to t he t o front halfs haft s .
The power trans fer unit has t he followi ng feat ures :
1500 Nm torque capaci ty2.58:1 output rat io to drive s haftOil fil led for lifeRemote breather.
The power trans fer unit has an internal beari ng pre-load s yst em. This al lows t he output s eal t o be changed in s ervi cewit hout di s turbi ng t he bearing pre-load.
POWER TRANSFER UNIT

ItemPart NumberDescription
1-Ri ght Hand (RH) half s haft2-Oil s eal
3-Taper rol ler bearing
4-Crown wheel drive gear5-Cas ing
6-O ring s eal
7-Taper rol ler bearings8-Oil s eal and fli nger
9-Oil s eal
10-Hous ing11-Bol ts
12-Pi nion gear
13-Col laps ible spacer14-Pre-l oad nut
15-Drive flange
16-Fl ange head bolt17-Oil s eal and fli nger
18-Transmis si on casi ng
19-Transmis si on different ialThe power trans fer unit compris es a crown wheel dri ve gear and a pinion gear dri ve shaft which are hous ed i n a cas ing.
The crown wheel dri ve gear i s mounted l ongi tudinall y acros s t he uni t. The Left Hand (LH) end of the gear has s plines whi chmat e wit h corresponding s pli nes in t he t rans mis s ion di fferenti al out put s l eeve. The dri ve gear i s hollow which all ows fort he fi tment of t he Right Hand (RH) hal f shaft . The half s haft i s located t hrough t he hol low drive gear and mat es wit hs plines i n t he transmis si on different ial . The hal f shaft is driven by t he transmis sion different ial and receives no drive from

t he power t rans fer unit .
The crown wheel is support ed in the cas ing on opposi ng t aper rol ler beari ngs whi ch are press ed i nto t he casi ng and t hehous i ng. The drive gear is retained i n t he cas i ng by a housi ng which i s bolt ed to the cas ing and s ealed wi th an O ring seal.The hous i ng is fit t ed wit h a t riple edge oi l seal and fl inger on the out er end of the hous ing which di rect dirt and mois tureaway from the area of the drive gear. Another s eal i s fit ted whi ch prevent s t he ingres s of dirt and mois t ure bet ween thedri ve gear and t he RH hal f shaft .
The pinion gear i s located i n t he hous ing at 90 degrees to the crown wheel drive gear. The pini on gear i s s upport ed i n t hecas i ng on oppos ing taper roll er bearings . The pi nion gear is retai ned in t he housi ng wit h a pre-l oad nut . The outer end oft he pinion gear is spl ined and mat es wit h t he dri ve shaft out put fl ange. The fl ange is s ecured wi th a fl anged bol t which iss crewed int o t he pinion gear.
A coll aps i bl e s pacer is locat ed between the out er t aper roll er beari ng and a s houlder on the pi nion gear. The coll aps ibl es pacer holds t he bearing i n ali gnment and al so col laps es under pres s ure appli ed to the pre-l oad nut . This all ows t hepre-load nut to be t ightened t o a predet ermi ned torque, which coll aps es t he s pacer, s et ti ng the correct bearing pre-loadand t he correct mes hi ng of the pi nion gear and crown wheel drive gear t eet h.
Dri ve from the t rans mis s ion di fferenti al drives t he crown wheel dri ve gear, which in turn rot ates t he pini on gear. Dri ve ispass ed from the pi nion gear to the drive s haft and t he rear different ial via the drive flange att ached to t he pini on gears haft.

Publi s hed: 25-Nov-2011
Transfer Case -
Lubricants, Fluids, Sealers and AdhesivesItemLand Rover Part No.
Input s haft s pli nes grease6G92M1C27AA
Power trans fer uni t fl ui d - vehicles wi th 3.2 pet rol and 2.2 di eselLR003137Power trans fer uni t fl ui d - vehicles wi th 2.0 pet rolLR003136
C apacitiesDescriptionLubricantCapacity (liters/pints/US quarts)
Power trans fer uni tBOT 118 PLUS 75W -900.75/1.3/0.79
General Specification
ItemRatio3.2 Pet rol aut o3.750:1
2.2 Dies el manual4.533:1
2.2 Dies el aut o3.329:12.0 Pet rol aut o2.583:1
Torque Specifications
DescriptionNmlb-ft
Axle mount ing bracket bolt s2418Oi l drain pl ug3526
Oi l fil ler plug3526
Pini on nut4835Power trans fer uni t front mount ing bracket heat s hiel d107
Power trans fer uni t bracket t o engine block bolt s6548
Power trans fer uni t bracket t o power trans fer uni t bol ts6548Power trans fer uni t to trans mi s si on hous i ng bol ts6548

Publi s hed: 11-May-2011
Transfer Case - Transfer Case
Des cript ion and Operat ion
For addit ional informat ion, refer t o: Four-W heel Drive Sys tems (308-07A Four-W heel Drive Sys tems, Des cript ion andOperat ion).

Publi s hed: 11-May-2011
Transfer Case - Transfer Case
Diagnosi s and Tes ti ng
Principles of Operation
For addit ional informat ion.
REFER to: Manual Transaxle and Clutch (308-00 Manual Transmis si on/Trans axl e and Cl ut ch - General Informat ion,
Diagnosi s and Tes ti ng).