Freelander 1. Manual - part 157

 

  Index      Land Rover     Freelander 1 - service manual 2002 year

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  155  156  157  158   ..

 

 

Freelander 1. Manual - part 157

 

 

INTERMEDIATE REDUCTION DRIVE

REPAIRS

41-21

Seal - pinion gear  

$% 41.29.04

Remove

1. Remove pinion housing.

 

 + 

 INTERMEDIATE REDUCTION 

DRIVE, REPAIRS, Seal - pinion gear 
housing - Td4.
 

 + 

 INTERMEDIATE REDUCTION 

DRIVE, REPAIRS, Seal - pinion gear 
housing - K1.8.
 

 + 

 INTERMEDIATE REDUCTION 

DRIVE, REPAIRS, Seal - pinion gear 
housing - KV6 - Non NAS.
 

 + 

 INTERMEDIATE REDUCTION 

DRIVE, REPAIRS, Seal - pinion gear 
housing - KV6 - NAS.

CAUTION: Before dismantling the pinion 
housing, measure the turning torque on 
existing bearings.

2. Attach pinion housing to suitable mounting 

plate and secure mounting plate in vice.

3. Check pinion torque to turn figure.

4. Reference mark pinion flange and pinion shaft 

for assembly purposes.

5. Restrain pinion flange using LRT-51-003.
6. 
Remove and discard nut.
7. Position pinion housing onto press, fit suitable 

adaptor on end of pinion shaft, press pinion 
shaft from drive flange and housing.

8. Remove and discard collapsible spacer.
9. Using a suitable lever, remove pinion oil seal. 

CAUTION: Take care to avoid damage to oil 
seal recess.

10. Remove pinion bearing inner race.

Refit

1. Clean pinion shaft, drive flange and housing.
2. Clean oil seal recess.
3. Lubricate and fit bearing to pinion housing.
4. Lubricate new seal.
5. Using a suitable adapter, press seal into 

housing.

CAUTION: Oil seal must be flush with end of 
pinion housing.

6. Assemble pinion to housing using new 

collapsible spacer.

7. Lightly lubricate drive flange splines with 

Molybdenum Disulphide grease.

8. Align pinion to drive flange reference marks 

and press flange onto pinion shaft until a 2 mm 
clearance exists in bearings.

9. Fit pinion assembly to mounting plate and 

secure in vice.

10. Fit new pinion nut, hold pinion drive flange 

using LRT-51-003 and tighten pinion nut to 150 
Nm (111 lbf.ft). 

11. Check pinion torque to turn figure. 

NOTE: Figure for new bearings is 180 to 200 
Ncm.

If original bearing figure is above 20 to 30 Ncm 
and below new bearing figure, set to figure 
recorded.

If original bearing is below 20 Ncm set to 20 to 
30 Ncm.

12. If turning torque is too low, carefully tighten nut 

and recheck reading. If turning torque is too 
high, pinion assembly will have to be 
dismantled and a new collapsible spacer fitted. 
Reassemble using new nut and recheck turning 
torque.

13. Check drive flange run-out using a Dial Test 

Indicator (DTI).

CAUTION: The drive flange run-out should 
not exceed 0.05 mm.

14. Remove pinion housing from vice and 

mounting plate.

INTERMEDIATE REDUCTION DRIVE

41-22

REPAIRS

15. Fit pinion housing.

 

 + 

 INTERMEDIATE REDUCTION 

DRIVE, REPAIRS, Seal - pinion gear 
housing - Td4.
 

 + 

 INTERMEDIATE REDUCTION 

DRIVE, REPAIRS, Seal - pinion gear 
housing - K1.8.
 

 + 

 INTERMEDIATE REDUCTION 

DRIVE, REPAIRS, Seal - pinion gear 
housing - KV6 - Non NAS.
 

 + 

 INTERMEDIATE REDUCTION 

DRIVE, REPAIRS, Seal - pinion gear 
housing - KV6 - NAS.

Seal - driveshaft - LH - Td4 & KV6 models

$% 41.29.08

Remove

1. Remove LH drive shaft.

 

 + 

 DRIVESHAFTS, REPAIRS, Shaft 

with both joints - LH.

2. Carefully remove and discard oil seal, take care 

not to damage oil seal recess.

Refit

1. Clean oil seal recess.

CAUTION: Oil seal is waxed on outer 
diameter and must not be lubricated before 
fitting.

2. Models with manual gearbox:Using LRT-54-

025 and LRT-99-003, fit new oil seal.

3. Models with automatic gearbox: Using LRT-

44-027, fit new oil seal.

INTERMEDIATE REDUCTION DRIVE

REPAIRS

41-23

4. Fit LH drive shaft.

 

 + 

 DRIVESHAFTS, REPAIRS, Shaft 

with both joints - LH.

5. Top-up gearbox fluid level.

 

 + 

 MAINTENANCE, MAINTENANCE, 

Automatic Gearbox – JATCO.

Seal - drive shaft - LH - K1.8

$% 41.29.08

Remove

1. Remove LH drive shaft.

 

 + 

 DRIVESHAFTS, REPAIRS, Shaft 

with both joints - LH.

2. Carefully remove oil seal from differential 

housing, discard oil seal.

Refit

1. Thoroughly clean oil seal recess in differential 

housing, splines and oil seal running surface on 
drive shaft.

2. Fit handle LRT-37-027 into seal replacer 

adaptor, LRT-37-032.

3. Position new oil seal onto LRT-37-032 with 

sealing lip facing towards differential housing.

4. Carefully drift oil seal into housing until fully 

seated in recess.

INTERMEDIATE REDUCTION DRIVE

41-24

REPAIRS

5. Fully insert oil seal protector tool, Unipart TRV 

100060, into differential oil seal so that oil seal 
lip is protected and that the split end of tool is 
butted correctly.

6. Fit LH drive shaft.

 

 + 

 DRIVESHAFTS, REPAIRS, Shaft 

with both joints - LH.

Seal - driveshaft - RH 

$% 41.29.09

Remove

1. Remove RH drive shaft.

 

 + 

 DRIVESHAFTS, REPAIRS, Shaft 

with both joints - RH.

2. Carefully remove and discard oil seal, take care 

not to damage oil seal recess.

Refit

1. Clean oil seal recess.

2. Locate seal on tool LRT-37-031 and replacer 

LRT-37-027 with sealing lip facing towards 
housing.

3. Carefully drift oil seal into housing until fully 

seated in recess.

4. Fit RH drive shaft.

 

 + 

 DRIVESHAFTS, REPAIRS, Shaft 

with both joints - RH.

 

 

 

 

 

 

 

Content   ..  155  156  157  158   ..