oil level LAND ROVER FRELANDER 2 2006 Repair Manual

Air condi ti oning unit s mus t not be li ft ed by t hei r hos es , pipes or capil lary li nes .Hos es and lines mus t not be s ubjected t o any t wis t or s tress ; t he efficiency of the s ys tem wil l be impai red by ki nksor res trict ions. Make s ure that hos es are correct ly pos it ioned before t ightening coupli ngs , and make s ure that allclips and support s are ut il is ed.Flexible hos es s houl d not be pos it ioned cl oser t han 100 mm (4.0 i n) t o t he exhaus t manifold unl es s protected byheat shi el ding.Complet ed ass embli es mus t be checked for refrigerat ion l ines t ouching met al panels . Any direct contact ofcomponents and panels may t rans mit nois e and s o must be el iminated.The appropri at e t orque wrench must be us ed when t ight eni ng refri gerant connect ions to t he s ti pul at ed value. Anaddi ti onal s panner mus t be us ed t o hold t he union t o prevent t wis ti ng of the pi pe when t ightening connect ions .Before connecti ng any hos e or pipe, make s ure that refri gerant oil is appli ed t o t he seat of t he new O-ri ngs , BUTNOT to the t hreads of the connect ion.All prot ect ive pl ugs or caps mus t remai n i n place in the component unt il i mmediat el y pri or to connect ion.Make s ure component s are at room temperat ure before uncappi ng/unpl uggi ng, t o prevent condens at ion of moi s turefrom the ai r that enters it .W hen di sconnect ing, immedi ately pl ug or cap all air condi ti oni ng pipes t o prevent ingres s of dirt and mois t ure i ntot he sys t em.Component s mus t not remain uncapped/unpl ugged, if a sys t em has been left uncapped/unpl ugged for 20 mi nut esor longer, a new recei ver/drier mus t be i ns t alled.The receiver/dri er contai ns des i ccant which absorbs mois t ure. It must be pos it ively sealed at al l ti mes . Areceiver/dri er t hat has been left uncapped for longer t han 20 mi nutes mus t not be used; i nst all a new uni t.The receiver/dri er s hould be the l ast component connect ed to the sys tem t o make s ure opt imum dehydrat ion andmaximum moi st ure protecti on of the sys tem.W henever a component of t he refrigerat ion s yst em is repl aced, it will al so be neces sary t o ins t al l a newreceiver/dri er uni t.Us e alcohol and a cl ean li nt -free cl oth to cl ean di rt y connecti ons.Make s ure t hat all new part s i ns t alled are marked for us e wit h R134a.W hen a major repai r has been complet ed, a leak t es t s hould be conduct ed; refer t o t he Repai rs Secti on of thi smanual for the correct procedure.
Refrigerant oil
CAUTION: Refrigerant oil eas il y absorbs water and mus t not be s tored for long periods. Do not pour unusedrefri gerant oi l back i nto the container. Always use an approved refrigerant oi l.
W hen replaci ng component s in the ai r condit ioning s ys tem, drai n t he refri gerant oi l from t he component being replacedint o a graduat ed cont ainer. On as s embly, add t he quant it y of refri gerant oi l drained t o t he new component - See Ai rCondi ti oni ng Compres s or Repl acement in this Sect ion.
Compres s or
A new compress or is sealed and press uris ed wit h Ni trogen gas . W hen i nst all ing a new compres sor, sl owly releas e thes eal ing cap; gas pres sure s houl d be heard to vent as t he s eal i s broken.
CAUTION: A new compress or s houl d always be s ealed and could be pres suris ed wit h ni trogen gas . To avoid pos si bleoil l os s , rel eas e t he s ealing cap(s ) s lowl y. Do not remove t he cap(s ) unt il i mmediatel y pri or to connect ing t he aircondi ti oni ng pipes t o the compress or.
Rapid refrigerant dis charge
If the ai r condit ioning s ys tem is i nvol ved in accident damage and t he s yst em is punct ured, t he refri gerant will di schargerapi dl y. The rapid di scharge of refrigerant wil l als o res ult in t he los s of mos t of the oi l from t he s yst em. The compres sormus t be removed and al l the remaining oi l in t he compres s or drained and refil led as i nst ruct ed in t he air condit ionings ect ion of t his manual.
Precaut ions for refrigerant recovery, recycl ing and rechargi ng
W hen t he air condit ioning s yst em is recharged, any exi s ti ng refri gerant i s first recovered from t he s ys t em and recycled.The s ys t em i s t hen charged wit h the required weight of refrigerant and volume of refrigerant oil .
W ARNING: Refri gerant mus t al ways be recycl ed before reus e t o make s ure that the purit y of the refrigerant i s highenough for s afe us e i n the ai r condit ioni ng sys t em. Recycl ing s hould al ways be carried out wit h equipment which i s des i gncert ifi ed by Underwrit er Laborat ory Inc. for compl iance wit h SAE J1991. Ot her equipment may not recycle refrigerant t o t herequired level of purit y.
• CAUTIO NS:
A R134a Refri gerant Recovery Recycli ng Rechargi ng Stat ion mus t not be us ed wit h any ot her t ype of refrigerant .Refrigerant R134a from domes ti c and commercial s ources mus t not be used i n mot or vehi cl e air condi ti oni ng s yst ems .
The s yst em must be evacuat ed i mmediat el y before recharging commences. Del ay bet ween evacuati on and rechargingis not permit ted.
Air Condit ioning Compress or Repl acement
A new compress or is suppli ed fi ll ed wit h a full charge (X cm³) of refrigerant oi l.
A calculat ed quant it y of oil mus t be drai ned from t he new compres s or before i nst all ing. To cal cul at e t he quant it y of oil t obe drai ned:
Remove the drain pl ug from the ol d compres sor.

Health Protection Precautions
Avoi d prol onged and repeat ed cont act wit h oil s, parti cularly us ed engine oi ls .W ear prot ect ive clot hing, including i mpervious gl oves where practi cable.Do not put oily rags i nt o pocket s .Avoi d contami nat ing cl ot hes, parti cularly underpants , wi th oi l.Heavi ly s oil ed clot hi ng and oil -i mpregnated foot wear s hould not be worn. Overall s mus t be cleaned regularly.First Ai d t reatment s hould be obt ained i mmediat el y for open cuts and wounds .Us e barrier creams , appl yi ng t hem before each work peri od, t o help the removal of oil from t he s ki n.W as h wi th soap and wat er to make s ure al l oi l is removed (s kin cl eans ers and nail brushes wi ll help). Preparati onscont aining lanol ine replace the nat ural s ki n oil s which have been removed.Do not us e gasol ine (pet rol ), keros ene (paraffin), di esel fuel (gas oi l), thi nners or s ol vent s for cleaning skin.If skin dis orders develop, obtain medical advice wi thout delay.W here practi cable, degreas e component s pri or t o handling.W here there is a ri s k of eye cont act , eye protecti on s houl d be worn, for exampl e chemical goggles or face s hiel ds ;in addi ti on an eye was h facil it y s houl d be provided.
Environmental Precautions
This s ecti on provides general informati on which can help t o reduce t he environment al i mpact s from the act ivit ies carriedout in workshops .
Emis s ions t o air
Many of the act ivit ies t hat are carried out i n works hops emit gas es and fumes whi ch can contribut e to global warmi ng,depl eti on of the ozone layer and/or the format ion of phot ochemical s mog at ground level. By cons ideri ng how t he works hopact ivi ti es are carried out , thes e gases and fumes can be mi nimi s ed, t hus reduci ng t he impact on t he envi ronment.
Exhaus t fumes
Runni ng car engines i s an es sent ial part of works hop act ivi ti es and exhaust fumes need t o be venti lated to at mos phere.However, the amount of t ime engi nes are runni ng and the pos it ion of t he vehi cle s hould be carefully cons idered at al lt imes , to reduce the releas e of poi s onous gas es and mini mis e t he i nconveni ence t o peopl e l iving nearby.
Solvent s
Some of t he cl eani ng agent s us ed are sol vent based and wil l evaporate rapidl y to atmos phere i f used carel ess l y, or i fcont ainers are l eft unseal ed. Al l contai ners mus t be firmly cl os ed when not requi red and s olvent should be used sparingly.W herever poss i bl e, sol vent s havi ng a l ow t oxi ci ty and flammabi li ty should be sel ect ed. Al ways foll ow t he ins t ructi onss uppl ied by t he s olvent manufact urer. Si mil arl y, many pai nt s are s olvent bas ed and the s pray s houl d be us ed in such away as t o reduce emi ss i ons t o a mini mum.
Refrigerant
It is i ll egal t o rel eas e any refrigerant int o t he atmos phere. Dis charge and repl acement of thes e mat eri al s from aircondi ti oni ng uni ts should onl y be carried out us ing t he appropri at e equipment .
Dis charges to water
Mos t works hops wi ll have t wo s ys t ems for di schargi ng wast e wat er - st orm drai ns and foul drains . Storm drains s houl d onlyreceive clean wat er i.e. rainwat er. Foul drai ns wil l accept many of the normal was t e wat er i .e. was hing wat er, detergent sand domest ic type was te BUT NOT oi l, petrol, s olvent , acids , hydraul ic fluid, anti freeze and si mil ar fl ui ds. If in doubt ,always cons ult the l ocal authori ty or wat er company.
Spill ages
Every precauti on mus t be taken t o prevent s pi ll age of oi l, fuel , sol vent s etc., reachi ng the drains . All handl ing of s uchmat erial s mus t take pl ace wel l away from drai ns and preferably i n an area wit h a s uit able contai ni ng wall t o preventdis charge int o drai ns or watercours es . If a spi llage occurs , it mus t be s oaked up immedi ately us i ng a s pil l ki t whereprovided.
Checkli s t
Spillage prevention:
Store li quids in a s ecure area.
Make s ure t hat taps on l iquid cont ai ners are s ecure and cannot be acci dent ally turned on.
Prot ect bulk st orage t anks from vandal is m by locki ng the val ves .
Trans fer li quids from one cont ai ner t o another i n an area away from open drai ns .
Ensure li ds are replaced s ecurel y on cont ainers .
Have s pi ll kit s availabl e near t o point s of s torage and liquid handl ing areas .
Spill Ki ts
Speci al mat eri als are avai lable to abs orb a number of di fferent subs tances. They can be in granular form, ready t o us e andare suppli ed in sui table cont ai ners . Dis posal of used spi ll absorbing mat eri al i s deal t wit h i n W as t e management .
Land contamination
Oil s , fuels and s olvents etc. can cont aminate any soi l wit h which t hey come int o cont act . Such materials MUST never bedis posed of by pouri ng on t o s oil and every precauti on mus t be t aken t o avoid s pil lage reaching s oil . W as te materials

Publi s hed: 11-May-2011
General Information - Road/Roller Testing
Des cript ion and Operat ion
Road or roll ing road t es t ing may be carri ed out for various reasons and a procedure det ail ing pre-t es t checks , throughengi ne s tarti ng and s topping, pre-driving checks , on-t es t checks to final checks on complet ion of t he tes t are given.
Unles s complete vehi cl e performance is bei ng checked, t he ful l road t est procedure need not be carried out . Ins tead, t hos eit ems part icularly relevant t o t he s yst em(s) bei ng checked can be ext racted.
Pre-Test Checks
W ARNING: If t he brake s yst em hydraul ic fluid level i s l ow, pedal travel i s exces si ve or a hydraulic leak is found, donot att empt to road t est t he vehicle unt il t he reas on for t he low fl ui d l evel, excess ive pedal travel or hydraulic leak isfound and rect ified.
It is s ugges t ed that pre-t es t and funct ional t es ts of t hose sys tems/circuit s whi ch affect t he safe and l egal operati ons oft he vehi cl e, s uch as brakes , light s and s teeri ng, should al ways be carri ed out before the road or roll ing road tes t .
Engi ne oil l evelEngi ne cool ant levelTires, for correct pres sure, compat ible types and tread patt erns , and wear wi thi n limi ts .There i s s ufficient fuel in the t ank to compl ete the t est .Check al l around the engine, t rans mis s ion and under the vehicle for oil , coolant , hydraul ic and fuel l eaks . Make anote of any apparent leaks and wipe off t he surrounding areas t o make it easi er to identi fy t he extent of the leakon complet ion of t he tes t.
Starting the Engine
• NOTE: On i nit ial dri ve away from cold and wit hi n t he fi rs t 1.5 km (1 mile), do not depress accelerat or pedal beyond halft ravel unt il t he vehi cl e has att ained a minimum s peed of 25 km/h (15 mil es /h). Never operat e at high engi ne speed or wi tht he accelerat or pedal at ful l travel whil st the engine i s cold.
With the ignition off, check:
The parking brake is appli ed.Automatic transmission: The s el ect or lever is i n 'P' - PARK.Manual transmission: The gear l ever i s in NEUTRAL.All i ns t rument gauges read zero.
With the ignition on, check:
Igni ti on cont roll ed warni ng li ght s come on.Engi ne t emperature gauge regis t ers a readi ng compat ibl e wi th t he engine t emperat ure.Fuel gauge regi st ers a reading appropriate to the fuel l evel i n t he tank.The operati on of the parki ng brake warning l ight and fl ui d l evel warni ng indicator light.
On Road Test Check:
CAUTION: At commencement of road tes ti ng, check the brake operati on while s ti ll travel li ng at low speed beforecont inuing wit h t he tes t. If t he brakes pul l to one si de, or appear to be ot herwi se fault y, do not cont inue wit h t he roadt es t unti l the fault has been found and rect ified.
The parking brake releas es completel y.Gear changing i s s mooth, and t here are no abnormal noi s es or vi brati ons from t he t rans mis s ion.The engi ne power out put is s ati s factory, accel erati on is smoot h and accel erator pedal operat ion is not s ti ff orheavy, and engi ne s peed ret urns t o idl e correctl y.There i s no exces s ive or abnormall y colored s moke from t he engi ne under normal driving, heavy l oad or overruncondi ti ons .Steering operat ion i s s moot h, accurat e, not exces s ively heavy or wit h exces s ive free pl ay or vibrat ion. Does not pul lt o one s ide and s elf centres smoot hly after corneri ng.All i ns t rument s regis t er the correct readi ngs and operate correctl y.Swit ches and controls operat e s moothl y and posi ti vel y, warning or i ndi cat or light s operate correctl y and thedirect ion i ndi cat or cont rol s elf cancels when the s t eering i s ret urned t o t he s traight ahead pos it ion.Heati ng and vent il at ion sys tems work correct ly and effect ively.Brakes operate efficientl y.
Brake Testing
Avoi d brake t es ti ng on busy roads where i t can caus e i nconveni ence or danger t o ot her road users.
CAUTION: Brake t es ti ng which i ncludes heavy brake appl icati ons should not be carri ed out wit h new brake pads /dis csunti l the component s have bedded-i n. New brake fri ct ion component s wi ll not reach ful l efficiency unt il t he beddi ng-inprocess is complet e. Not e t hat when new parking brake shoes or rear brake di scs have been ins t al led, it i s es sent ial thatt he 'beddi ng-in' procedure i s carri ed out.For addit ional informat ion, refer t o: Parking Brake Shoes Bedding-In (206-05 Parking Brake and Actuati on, GeneralProcedures).
Test t he brakes at s everal speeds wit hin the normal operat ing range usi ng both light and heavy pedal pres s ure. Note anyt endency to snat ch, pull or drag, and any undue del ay in appli cat ion or release.

Publ is hed: 24-Jun-2011
Jacking and Lifting - Jacking
Des cript ion and Operat ion
General
W ARNING: The foll owing i nst ructi ons mus t be adhered to before rais i ng the vehicle off t he ground:
Posi ti on vehi cl e on a sol id, level surface.Apply t he parking brake.Select 'P' - PARK on automat ic t rans mis s ion sel ect or.Select 'N' - Neutral on manual t rans mis s ion.
W ARNING: If t he dri ve s haft(s ) are t o be di sconnect ed, i t wil l be neces s ary t o rai s e all four wheels off the ground inorder t hat t he s haft (s ) can be rot ated. DO NOT us e the cus tomer jack and ens ure that t he vehi cl e is adequatel y s upport edon axle s t ands . W i th the vehicle rai sed, it will be necess ary to releas e t he park brake and sel ect Neutral - 'N' in the mai nt ransmis s ion t o enabl e t he dri ve s haft(s ) to be rot ated.
• CAUTIO NS:
To avoid damage t o t he underbody components of t he vehi cle, the foll owing i ns t ructions mus t be adhered to:
Do not pos it ion jacks or axle s t ands under the foll owing component s :
Body s truct ure ot her t han any approved jacki ng or li ft ing point sRear subframeBumpersFuel l inesFuel t ankBrake l inesFront or rear s uspens ion armsSteering l inkageRear di fferenti al uni tTrans mis s ionEngi ne oil pan - See not e below
• NOTE: For certain repair operat ions, i t may be necess ary to support t he engine under t he oil pan. In thi s cas e, a bl ock ofhardwood or a rubber pad mus t be pos it ioned on t he jack li ft ing pad t o protect the oi l pan.
Hydraulic jack
• W ARNINGS:
Before commenci ng work on undersi de of vehi cl e, ens ure that axle s t ands are correctly pos it ioned and vehi cle i ss ecurel y s upported.
Al ways chock the rear wheel s when jacking t he front of the vehicle.
A hydrauli c jack wi th a mi ni mum li ft ing capacit y of 1500 kg, (3,300 l bs) must be us ed.
Raising and Supporting the Vehicle
To as si s t in rais ing the vehicle, us e t he cus t omer jacki ng poi nts on the s i ll or on t he trolley jack pos i ti on at the rear of t hefront subframe as indicated i n t he fol lowing ill ust rat ions .
Raising the front of the vehicle
W ARNING: Always chock t he rear wheels when jacki ng the front of t he vehi cl e.
Apply t he parking brake.
Select 'P' - Park on aut omat ic trans mi s si on s el ect or.
Select 'N' - Neutral on manual t rans mis s ion.

Check t hat the flui d level is t o t he mi d-way mark between the MAX and MIN marks on t he fluid res ervoir, t op-up i fneces s ary.Clean t he area around the res ervoi r fi ll er cap, remove cap.
CAUTION: Do not fill reservoir above the MAX mark.
If necess ary, t op-up us ing t he recommended fluid to the mid-way mark on the reservoir.For addit ional informat ion, refer t o: Specificati ons (211-02 Power St eering, Specificati ons).Ins t all the res ervoir fill er cap.
Windshield Washer Reservoir
Remove the winds hi eld was her res ervoir fill er cap.Top-up t he res ervoir us ing a mi xt ure of an approved wi nds hiel d was her flui d and water unti l the level i s t o thebott om of t he gauze fil ter i n t he res ervoir fil ler neck.Ins t all the res ervoir fill er cap.
Engine Oil and Filter
CAUTION: For vehi cl es operati ng under arduous condi ti ons s ee relevant s ecti on.
Every 6 months or 7,500 miles (12,000 km): NAS and Gulf markets Renew engi ne oil and filt er.For addit ional informat ion, refer t o: Specificati ons (303-01A Engine - I6 3.2L Petrol, Speci fi cat ions).
Air Filtering
CAUTION: For vehi cl es operati ng under arduous condi ti ons s ee relevant s ecti on.
1. Every 2 years or 30,000 miles (48,000 km): Replace the ai r cl eaner element .For addit ional informat ion, refer t o: Air Cl eaner (303-12A Int ake Ai r Dis t ri but ion and Fi lt ering - I6 3.2L Petrol , Removal andIns t allat ion).
Automatic Transmission
Every 10 years or 150,000 miles (240,000 km): Renew automat ic t rans mis s ion flui d.For addit ional informat ion, refer t o: Specificati ons (307-01 Aut omati c Trans mis s ion/Transaxle, Speci fi cat ions ).
Manual Transmission
Every 10 years or 150,000 miles (240,000 km): Renew manual t rans mi ss ion fl ui d.For addit ional informat ion, refer t o: Specificati ons (308-00 Manual Trans mis s ion/Transaxle and Clutch - GeneralInformat ion, Speci ficat ions).
Power Transfer Unit
Every 10 years or 150,000 miles (240,000 km): Renew power t rans fer unit oi l.For addit ional informat ion, refer t o: Specificati ons (205-03, Speci fi cat ions ).
Differential Assembly - Rear
Every 10 years or 150,000 miles (240,000 km): Renew rear different ial oil .For addit ional informat ion, refer t o: Specificati ons (205-02 Rear Drive Axle/Different ial, Specifi cat ions ).
Suspension and Body Mountings

Ensure that the steering wheel is in the straight ahead position, do not turn the st eering w heel prior to checking the
fluid level.
Check t hat the flui d level is t o t he mi d-way mark between the MAX and MIN marks on t he fluid res ervoir, t op-up i f
neces s ary. Clean t he area around the res ervoi r fi ll er cap, remove cap.
CAUTION:
Do not fill reservoir above the MAX mark.
If necess ary, t op-up us ing t he recommended fluid to the mid-way mark on the reservoi r.
For addit ional informat ion, refer t o: Specificati ons (211-02 Power St eering, Specificati ons).
Ins t all the res ervoir fill er cap.
Windshield Washer Reservoir
Remove the winds hi eld was her res ervoir fill er cap.
Top-up t he res ervoir us ing a mi xt ure of an approved wi nds hiel d was her flui d and wate
r unti l the level i s t o the
bott om of t he gauze fil ter i n t he res ervoir fil ler neck. Ins t all the res ervoir fill er cap.
Engine Oil and Filter
• CAUTIO NS: For vehi cl es operati ng under arduous condi ti ons see relevant secti on.

Vehicles operating on high sulphur content fuel - above 0.7%, the oil and filter cha nge period MUST NOT
exceed 3 months or 3,750 miles (6,000 km).
Vehicles operating on moderate sulphur content fuel - 0.3 to 0.7%, the oil and filte r change period MUST NOT
exceed 6 months or 7,500 miles (12,000 km).
Renew engi ne oil and fil ter.
For addit ional informat ion, refer t o: Oil Fil ter El ement (303-01A Engine - I6 3.2L Pet rol , Removal and Ins t allat ion).
Air Filtering
CAUTION: For vehi cl es operati ng under arduous condi ti ons s ee relevant s ecti on.
1. Every 2 years or 30,000 miles (48,000 km): Replace the ai r cl eaner element .
For addit ional informat ion, refer t o: Air Cl eaner (303-12B Int ake Ai r Dis t ri but ion and Fi lt ering - TD4 2.2L Di es el, Removal
and Ins t allat ion).
Fuel Filter
1. Every year or 15,000 miles (24,000 km): Drai n water from the fuel fi lt er.
1. Every 2 years or 30,000 miles (48,000 km): Replace fuel fi lt er el ement.
For addit ional informat ion, refer t o: Fuel Fil ter (310-01B Fuel Tank and Lines - TD4 2.2L Dies el, Removal and Ins tall ati on).
Automatic Transmission
Every 10 years or 150,000 miles (240,000 km): Renew automat ic t rans mis s ion flui d.

Bearing Rumbl e
Bearing rumble s ounds l ike marbl es being t umbled. Thi s condi ti on is us uall y caus ed by a worn/damaged wheel bearing.The lower pit ch is because the wheel bearing turns at onl y about one-t hird of the drives haft s peed. W heel bearing nois eals o may be high-pi tched, s imil ar t o gear noi s e, but wi ll be evident in al l four drivi ng modes.
Symptom Chart
SymptomPossible CauseActionNois e i s at cons t ant t oneover a narrow vehi cl e s peedrange. Us ual ly heard onl ight drive and coas tcondi ti ons
Rear drive axl eFor addi ti onal i nformat ion. GO to Pi npoi nt Tes tA.
Nois e i s t he s ame on driveor coas tRoad nois eW orn or damaged dri ves haftjoi ntDriveshaft cent er beari ngW heel bearing
Normal condit ion (road noi se)Check and ins tal l new components a required.REFER t o:Driveshaft - Vehi cl es W i thout: Di eselPart iculat e Fil ter (DPF) (205-01Driveshaft, Removal and Ins tall ati on),Rear W heel Bearing (204-02 RearSus pens ion, Removal and Inst all at ion),Front W heel Bearing (204-01 FrontSus pens ion, Removal and Inst all at ion).
Nois e i s produced wit h t hevehicle s t ati onary andwhen driving
EngineTrans mi ss ionFor addi ti onal i nformat ion. REFER to:Engine (303-00 Engine Syst em - GeneralInformat ion, Di agnos is and Tes ti ng),Di agnos ti cs (307-01 Aut omati cTrans mi ss ion/Transaxle, Di agnos is andTes ti ng).
Loud clunk in the driveli newhen s hifti ng from revers et o forward
Trans mi ss ion cal ibrat ionTrans mi ss ion MountTrans mi ss ionSus pens ion component sBackl ash in t he dri vel ineEngine i dl e s peed s et t oo highEngine mount
Us i ng the manufact urer approved diagnos t ics ys tem, re-configure t he Transmis s ion ControlModule (TCM) wi th the l ates t avai lablecali brati onIns pect and ins t al l new t ransmis s ion mount sas requi redFor t ransmis s ion diagnos ti cs .REFER t o: Diagnos t ics (307-01 Automat icTrans mi s si on/Trans axl e, Diagnos is andTes ti ng).Ins pect and ins t al l new s uspens ioncomponent s as requi redIns pect and ins t al l new dri vel ine component sas requi redCheck and adjus t the i dle s peed as requi redIns pect and ins t al l new engi ne mounts asrequi red
Cli cki ng, popping, orgri nding nois esInadequate or contami nat edl ubricati on in the front /reardri ve halfshaft cons tant veloci ty(CV) jointAnother component cont act ingt he front/rear dri ve hal fs haftW heel bearings , brakes ors uspens ion component s
Ins pect, cl ean and lubri cat e wit h new greaseas requi redEns ure al l ot her components are clear fromfront /rear drive halfs haftIns pect and ins t al l new components asrequi red
Vibrati on at highways peedsOut of balance wheel (s ) ort ire(s )Driveshaft mis ali gned/out ofbalanceDriveshaft cent er beari ngt ouching body mount ing point
Bal ance and i ns t all new wheel(s ) and ti re(s) asrequi red.REFER t o: W heel and Ti re (204-04 W heel s andTi res , Removal and Ins t allat ion).Check dri ves haft ali gnment . Check drives haftbalance us ing manufact urer approveddi agnos ti c s ys t emCheck dri ves haft ali gnment
Shudder, Vibrat ion DuringAccel erati onPowert rai n/dri vel inemi s al ignmentHi gh cons tant velocit y (CV) jointoperat ing angles caus ed byi ncorrect ride hei ght
Check for powert rai n/dri vel ine mis alignmentand rect ify as requi red. Ins t al l newcomponent s as requi redCheck the ri de hei ght and verify the corrects pri ng rat e. Ins t al l new components asrequi red
Lubricant LeakRear drive axl e breatherDamaged s ealRear drive axl e fi ll er pl ugRear drive axl e cover/acti veon-demand coupl ing joint
Check oil level and correct as neces s aryIns tall new drives haft/pinion seal as required.REFER t o: Act ive On-Demand Coupl ing DrivePi ni on Seal (205-02 Rear Dri veAxle/Different ial , Removal and Ins t al lat ion).Check and ins tal l new fi ll er pl ug as requiredRe-seal leaking joint s as required

Pos it ion a contai ner t o coll ect t he oil s pill age. Di scard the O-ring s eal.6.
Installation Lubricat e and ins tal l a new O-ri ng s eal .
Refer t o: Specificati ons (205-02 Rear Drive Axle/Different ial,
Speci fi cat ions ).
1.
2. CAUTION: Make s ure that the area around t he component is
clean and free of foreign materi al.
Inst all t he act ive on-demand coupli ng.
T orque: 24 Nm 2.
Connect t he electrical connect or.
3. 4. CAUTION: Make s ure t hat new bolt s are
ins tal led.
• NOTE: Make s ure t hat the component i s i ns t alled to
the pos it ion not ed on removal .
Ins t al l the drives haft to the act ive on-demand
coupli ng.
T orque: 40 Nm 4.
Inst all t he dri ves haft rear s upport bracket .
T orque: 35 Nm 5.
Check and top-up the acti ve on-demand coupl ing fluid level.
Refer t o: Act ive On-Demand Coupl ing Fi lli ng (205-02 Rear Drive
Axle/Different ial, General Procedures).
6.

Pos it ion a contai ner t o coll ect t he oil s pill age. Us ing t he s peci al t ool, remove the drive flange.
Speci al Tool (s ): 205-053 Di scard the nut .5.
Installation 1. W ARNING: Make sure t hat a new nut is i nst all ed.
Us ing t he s peci al t ool, i ns t all the drive flange.
Speci al Tool (s ): 205-053 T orque:
130 Nm 1.
2. CAUTION: Make s ure t hat new bolt s are
ins tal led.
• NOTE: Make s ure t hat thes e component s are
ins tal led t o t he noted removal pos it ion.
Ins t al l the drives haft to the act ive on-demand
coupli ng.
T orque: 40 Nm 2.
Inst all t he dri ves haft rear s upport bracket .
T orque: 35 Nm 3.
Check and top-up the acti ve on-demand coupl ing fluid level.
Refer t o: Act ive On-Demand Coupl ing Fi lli ng (205-02 Rear Drive
Axle/Different ial, General Procedures).
4.
Inst all t he exhaus t sys t em.
5.

13. W ARNING: Manual transmis s ion: Fl uid l oss isunavoi dabl e, us e abs orbent cl oth or a cont ai ner t ocollect t he fl uid.
13.
Installation
1. NOTE: Do not ful ly engage the hal fs haft unti l the oi ls eal protector has been removed.
To prevent oil s eal damage us e t he prot ect or wheni ns t alli ng t he shaft int o the trans mi s si on. It is not as peci al t ool but i s avai lable from t he Part s Catal ogue.
1.
2. CAUTIONS:
Ins tall t he halfshaft nut finger ti ght .
Do not us e ai r tools to i nst all t he nut. Fail ure t o follow thi si ns t ructi on may resul t in damage t o t he component.
To i nst all , revers e t he removal procedure.
2.
Manual t rans mi ss i on vehi cl es onl y: Check and t op-up t het rans mis s ion flui d level.
Refer t o: Transmis s ion Flui d Level Check (308-03 ManualTrans mi ss ion/Transaxle, General Procedures).
3.