boot LAND ROVER FRELANDER 2 2006 User Guide

Speci al Tool (s ):
303-D121 7.
Installation 1. CAUTION: Extreme cleanli nes s mus t be exercis ed when
handl ing t hese components .
Clean and i nspect the components for det eri orati on.
1.
Inst all t he inner and out er CV boots ont o t he hal fs haft .
2.
3. NOTE: Ins t al l a new retaini ng clip.
Inst all t he inner CV joi nt inner ont o t he halfshaft .
3.
4. CAUTION: Make s ure that thes e component s are ins tall ed t o
t he noted removal pos it ion.
Inst all t he inner CV joi nt out er ont o t he halfshaft.
4.
Pack the i nner CV joint wi th the grease suppli ed.
5.
Pack the out er CV joi nt wit h t he grease s uppli ed.
6.
7. NOTE: Ins t al l new ret aining cl ips .
Secure t he inner CV joi nt boot t o t he inner CV joint.
7.
8. NOTE: Ins t al l new ret aining cl ips .
Secure t he outer CV joint boot to t he outer CV joint .
8.
Inst all t he RH halfs haft.
Refer t o: Front Halfs haft RH (205-04 Front Dri ve Halfs haft s , Removal
and Inst all at ion).
Refer t o: Front Halfs haft LH (205-04 Front Drive Hal fs haft s , Removal
and Inst all at ion).
9.

Publi s hed: 11-May-2011
Rear Drive Halfshafts -
General SpecificationItemSpecification
TypeFully fl oat ing, s ol id shafts wi th inner and out er cons tant velocit y joi nts
Recommended Lubricant
ItemSpecification
Inboard joi ntUse greas e s uppl ied wi th replacement boot kitOut board joi ntUse greas e s uppl ied wi th replacement boot kit
Torque Specifications
DescriptionNmlb-ft
Halfs haft nut*+395291* New nuts/bolts must be fitted
+ Stake nut on completion

Publi s hed: 11-May-2011
Rear Drive Halfshafts - Inner Constant Velocity (CV) Joint Boot
Removal and Inst all ati on
Special T ool(s)
303-D121Pull er, General Purpose
Removal
1. W ARNING: Make sure t o s upport the vehicle wit h axles tands .
Rais e and s upport t he vehi cl e.
1.
Remove t he hal fs haft .
Refer t o: Rear Hal fs haft LH (205-05 Rear Dri ve Halfs haft s , Removaland Inst all at ion).
2.
3. NOTE: Dis card t he ret aining cl ips .3.
4.

5.
NOTE: Dis card t he ret aining cl ip.
5. Speci al Tool (s ):
303-D121 6.
Installation 1. CAUTION: Extreme cleanli nes s mus t be exercis ed when
handl ing t hese components .
Clean and i nspect the components for det eri orati on.
1.
Inst all t he inner CV boot ont o t he halfshaft .
2.
3. NOTE: Ins t al l a new retaini ng clip.
Inst all t he inner CV joi nt inner ont o t he halfshaft .
3.
4. CAUTION: Make s ure that thes e component s are ins tall ed t o
t he noted removal pos it ion.
Inst all t he inner CV joi nt out er ont o t he halfshaft.
4.
Pack the i nner CV joint wi th the grease suppli ed.
5.
6. NOTE: Ins t al l new ret aining cl ips .
Secure t he inner CV joi nt boot t o t he inner CV joint.
6.
Inst all t he hal fs haft .
7.

Publi s hed: 11-May-2011
Rear Drive Halfshafts - Outer Constant Velocity (CV) Joint Boot
Removal and Inst all ati on
Special T ool(s)
303-D121Pull er, General Purpose
Removal
• NOTE: The outer Const ant Veloci ty joint mus t not be removed from t he s haft. The i nner joint and gait er have t o beremoved t o faci lit ate gai ter repl acement of t he out er C. V. gai ter. The inner and out er gai ters are suppli ed toget her as akit .
1. W ARNING: Make sure t o s upport the vehicle wit h axles tands .
Rais e and s upport t he vehi cl e.
1.
Remove t he hal fs haft .
Refer t o: Rear Hal fs haft LH (205-05 Rear Dri ve Halfs haft s , Removaland Inst all at ion).
2.
3. NOTE: Dis card t he ret aining cl ips .3.
4. NOTE: Dis card t he ret aining cli ps.4.

5.
6.
NOTE: Dis card t he ret aining cl ip.
6. Speci al Tool (s ):
303-D121 7.
Installation 1. CAUTION: Extreme cleanli nes s mus t be exercis ed when
handl ing t hese components .
Clean and i nspect the components for det eri orati on.
1.
Inst all t he inner and out er CV boots ont o t he hal fs haft .
2.
3. NOTE: Ins t al l a new retaini ng clip.
Inst all t he inner CV joi nt inner ont o t he halfshaft .
3.
4. CAUTION: Make s ure that thes e component s are ins tall ed t o
4.

t he noted removal pos it ion.
Inst all t he inner CV joi nt out er ont o t he halfshaft.
Pack the i nner CV joint wi th the grease suppli ed.5.
Pack the out er CV joi nt wit h t he grease s uppli ed.6.
7. NOTE: Ins t al l new ret aining cl ips .
Secure t he inner CV joi nt boot t o t he inner CV joint.
7.
8. NOTE: Ins t al l new ret aining cl ips .
Secure t he outer CV joint boot to t he outer CV joint .
8.
Inst all t he hal fs haft .
Refer t o: Rear Hal fs haft LH (205-05 Rear Dri ve Halfs haft s , Removaland Inst all at ion).
9.

3-Dus t s hiel d
4-Dus t s hiel d ret aining s crew (3 off)
5-Brake dis c6-Brake dis c ret aini ng screw
7-Outer anti -s queal s him
8-Outer brake pad9-Inner brake pad
10-Inner ant i-s queal s him
11-Cal iper hous i ng spring12-Fi xed carri er
13-Cal iper pis ton seal
14-Cal iper pis ton15-Sl idi ng cal iper
16-Bus hed bolt rubber boot (2 off)
17-Bus hed bolt (2 off)18-Bus hed bolt dus t cap (2 off)
19-Cal iper bleed s crew
20-Bleed s crew cap21-Fl exi ble hos e
22-Fi xed carri er retai ni ng bolt (2 off)
23-Front Left-Hand (LH) wheel knuckle
OVERVIEW
The front brake as sembl y feat ures a venti lat ed brake dis c and cast -iron sl idi ng cal iper wit h s ingle act ing pi st on.
BRAKE DISC
ItemPart NumberDescription
A-Front brake dis c - i 6 gas ol ine vehicleB-Front brake dis c - TD4 di esel vehicle
The brake dis c i nst all ed to the 3.2 l it er i 6 gas ol ine vehicle is 316 x 28 mm (12.44 x 1.10 i n) diameter. The brake dis cins t al led t o t he 2.2 li ter TD4 dies el vehi cl e is 300 x 28 mm (11.81 x 1.10 in) diamet er. The brake di sc is s ecured t o thewheel knuckl e hub wi th a s ingle s crew and is al so ret ai ned by t he 5 wheel securi ng nut s .
Both types of front brake dis c are manufact ured wi th vent il at ion channel s , al lowi ng the di s c to achieve hi gh levels oft hermal st abil it y even during s evere braki ng.
The dis c i s cool ed as the forward mot ion of t he vehi cl e draws air t hrough the venti lat ion channel s, and acros s t he s urfacesof the di s c.
CALIPER ASSEMBLY

ItemPart NumberDescription
A-Front brake cal iper - i6 gas oli ne vehi cl eB-Front brake cal iper - TD4 dies el vehicle
The cal iper as sembl y compris es a fixed carrier and s li ding caliper. The fi xed carrier i s mounted t o s t raddle t he brake di scand is at t ached t o t he wheel knuckl e wit h 2 bol ts . The fixed carri er provides the locat ion for 2 brake pads t hat aremounted on ei ther s ide of t he brake di sc, and is formed wit h guide channel s t hat al low t he brake pads t o s li de toward t hedis c s urface.
• NOTE: The 2 fixed carrier ret aining bol ts are pre-appl ied wi th a t hread locking adhesi ve and mus t not be re-us ed duringmaint enance. New fixed carri er ret ai ning bolt s mus t be us ed and t he ori gi nal bolt s di scarded.
The s li di ng cal iper is mount ed over the fixed carrier and ret ains t he 2 brake pads wi thi n the cal iper as s embly. The s li di ngcal iper is secured t o t he fixed carri er wit h 2 bus hed bol ts , and i s formed wi th a hydraul ic chamber cont ai ning a 60 mm(2.36 in) di ameter pis t on and annular s eal.
The s li di ng cal iper is connect ed via a fl exi ble hos e t o t he brake s yst em hydrauli c circui t, and als o i ncorporates a bleeds crew for maint enance purposes .
The 2 bus hed bol ts are machined wi th a s mooth surface and are protect ed from di rt and moi st ure ingres s wi th a col laps iblerubber boot . The bushed bolt s all ow t he s li di ng caliper li mi ted l ateral movement along t he fi xed carri er.
A hous ing s pri ng is locat ed on t he outer s ide of t he brake dis c, and is connect ed wit h formed hooks between t he fixedcarri er and sl idi ng cal iper. During operat ion of t he brake, t he s pri ng is tens ioned as the sl iding cal iper moves toward thebrake dis c. The s pring as s is t s to move t he sl idi ng cal iper away from t he brake di sc as the brake is released.
An anti -s queal s him i s ins tal led on t he outs i de edge of each brake pad and reduces Nois e, Vibrat ion and Hars hnes s (NVH)from the brake component s duri ng operati on.
The brake pads are not i nst all ed wit h pad wear s ens ors .
BRAKE DUST SHIELD
A formed brake dust s hiel d is locat ed between t he wheel knuckle and brake di s c, and i s s ecured to the knuckl e wit h 3s crews .
The brake dus t shi eld i s handed t o t he rel evant s ide of t he vehicle and protects t he brake component s from cros s axl es tone t hrows . The brake dus t shi el d als o prevent s debris and brake dust from s preading t o other part s of t he vehi cl e.
PRINCIPLES OF OPERATION
Brake Application
As t he brake pedal i s applied, ini ti al hydrauli c pres s ure i s fel t in the s l iding cali per chamber caus ing t he pis t on to ext endt oward t he brake dis c. The moving pis t on cont act s t he inner brake pad, forci ng the pad al ong the fixed carrier guidechannels and i nto cont act wi th the i nner s ide of t he brake di sc.
As t he pis ton ext ends from t he cal iper chamber, it pas ses t hrough an i nternal annul ar seal located wit hi n t he cal iper

5
-Dus t s hi eld retai ni ng s crew (4 off)
6 -Brake di sc – s olid (TD4 di esel vehi cle)
7 -Brake di sc ret ai ning s crew
8 -Brake di sc – vent il ated (i6 gas oli ne vehi cl e)
9 -Fixed carrier
10 -Bus hed bol t rubber boot (2 off)
11 -Bus hed bol t
12 -Cali per pi st on s eal
13 -Brake pad retai ni ng s pri ng (2 off)
14 -Out er ant i-squeal shi m
15 -Cali per pi st on
16 -Out er brake pad
17 -Inner brake pad
18 -Sli ding cali per
19 -Inner anti -s queal s him
20 -Cali per bl eed screw
21 -Bleed s crew cap
22 -Bus hed bol t ret aining s crew (2 off)
23 -Rear Left-Hand (LH) wheel knuckle
24 -Fixed carrier ret aining bol t (2 off)
25 -Anti -l ock Brake Syst em (ABS) s ens or ret aining s crew
OVERVIEW
The rear brake as s embly feat ures ei ther a convent ional venti lat ed or a s olid type br ake di s c, and cast -iron sl idi ng cal iper
wit h s i ngl e act ing pi s ton.
BRAKE DISC Item
Part Number Description
A -Rear brake dis c - i 6 gas ol ine vehicle
B -Rear brake dis c - TD4 di esel vehicle
The vent il ated t ype brake dis c i s 302 x 20 mm (11.89 x 0.79 in) i n diamet er and ins t al led t o t he 3.2 l it er i6 gas oli ne
vehi cl e. The sol id t ype brake dis c i s 302 x 12 mm (11.89 x 0.47 i n) i n diamet er and ins tal led t o t he 2.2 lit er TD4 dies el
vehi cl e. The brake dis c i s s ecured to t he wheel knuckle hub wi th a s ingle screw and is al s o ret ained by t he 5 wheel
s ecuring nuts .
Both si zes of rear brake dis c are suffi ci ent ly cooled to achieve high level s of t her mal st abil it y, even duri ng s evere braking.
The s olid type brake di sc is cooled as t he vehi cles forward moti on direct s air over the di sc surfaces . The convent ional
vent il ated di sc is cooled by t he forward moti on of the vehicle drawing ai r through r adial s lots formed on t he dis c outer rim.
The air cools t he dis c from the i nsi de edge to the di s c cent er, before vent ing out t hrough s lots formed around t he dis c
cent ral bell .