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Land Rover Freelander 1997-2006 Workshop Repair Manual
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on PDF can be viewed using free PDF reader like adobe , or foxit or nitro . File size 146 Mb Searchable PDF document with bookmarks. This Workshop Manual is for the following Land Rovers made between 1997-2006
Engine and Transmissions covered by this manual: Engines
Transmissions
Contents
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Tools & consumables (minimum)
- Vehicle jack + 4 jack stands or full two-post lift. Transmission jack or heavy-duty floor jack with wood block.
- Engine support bar or engine hoist (if required to lower gearbox).
- 1/4", 3/8", 1/2" drive socket sets (metric), long extensions, universal joints.
- Torx, hex/allen, and spline/OE driver set (as applicable).
- Impact wrench and breaker bar.
- Torque wrench (range to at least 200 Nm).
- Oil drain pan, funnels, rags, brake cleaner/parts solvent.
- Snap-ring pliers (internal & external).
- Bearing puller / three-jaw puller.
- Hydraulic or arbor press (or bench press) and soft jaws.
- Drift punches, brass/nylon punch, soft mallet.
- Seal puller and seal driver set.
- Circlip pliers, punches, small pry bars.
- Dial indicator with magnetic base (for backlash).
- Micrometer or calipers (for shim thickness, gear tooth thickness).
- Plastigage (optional, for clearances).
- Clean bench, parts trays, marking pen/paint.
- New transfer case/gearbox oil and sealant (Loctite 518 or OEM gasket if required).
- New replacement parts: planetary gear set (sun gear, planets, carrier, ring gear as a set or matched kit), planet bearings/bushes, thrust washers, carrier bearings, seals, O-rings, circlips, shims, fasteners (often replace bolts). Also consider replacement bearings in adjacent assemblies if worn.
- Workshop manual for vehicle-specific torque/specs and shim/backlash targets.
Safety precautions
- Work on level ground, use jack stands — never rely on a jack alone.
- Disconnect battery before starting.
- Support engine or transmission correctly; transfer cases are heavy—use a transmission jack.
- Wear safety glasses, gloves, protective footwear.
- Keep work area clean; do not allow dirt into gearsets.
- Use correct lifting technique and team-lift heavy parts.
- Mark orientation of components and take photos/notes during disassembly to ensure correct reassembly.
Overview (what you’re doing)
- Remove the transfer case / gearbox from the vehicle, disassemble to access planetary assembly, remove the old planetary set & bearings, press-in/install new gears/bearings, set correct shim/backlash and bearing preload, reassemble, refill fluids, test.
Step-by-step workshop procedure
1. Prepare vehicle
1.1 Park on level surface, chock wheels, disconnect negative battery.
1.2 Lift vehicle on hoist or raise and support on jack stands. Remove protective skid plates as needed.
1.3 Drain transfer case/gearbox fluid into pan; replace drain plug.
2. Remove transfer case / remove from vehicle
2.1 Support transmission/transfer case with transmission jack.
2.2 Unbolt propshaft(s)/driveshafts from transfer case flanges; tag and hang driveshafts aside.
2.3 Disconnect electrical connectors (sensors, switch), vacuum/pneumatic lines, linkage, and any cooling lines.
2.4 Unbolt transfer case-to-transmission (or adaptor housing) bolts. Support both sides to avoid stress.
2.5 Lower transfer case assembly carefully and remove to clean bench.
3. Strip external parts and prepare for disassembly
3.1 Clean exterior to reduce contamination upon opening.
3.2 Remove external covers, oil pump (if fitted), selector forks/covers as per manual.
3.3 Keep fasteners organized and labelled.
4. Disassemble transfer case to access planetary assembly
4.1 Remove snap rings/circlips retaining shafts and carriers using snap-ring pliers.
4.2 Pull out input/output shafts carefully; use puller if required. Mark orientation.
4.3 Remove carrier bolts and withdraw planet carrier assembly. Use press or gentle tapping as required.
4.4 Remove ring gear if separate; some units are integral to housing—follow manual.
4.5 Inspect bearings, bushings, thrust washers, and seals as you remove parts.
Tool use notes:
- Bearing puller: position puller evenly on bearing inner race and pull with steady pressure. Use backing plate under gearbox housing to avoid distorting housing.
- Press: use correct adapters and support carrier to press out bearings; apply steady pressure not shock. Warm bearings/housings slightly (oil bath) to ease fit if permitted by manual.
- Snap-ring pliers: compress ring fully before attempting removal to avoid deformation.
5. Inspect removed parts
5.1 Clean parts in solvent and inspect gear teeth for pitting, wear, or chipped teeth.
5.2 Measure bearings for play; check races for scoring.
5.3 If any bearing or race shows wear, replace. Planetary gears should be replaced as a matched set (sun/planet/ring) to preserve tooth profile.
5.4 Confirm replacement kit contents: planet gears, planet pins/shafts, planet bearings/bushings, sun gear, carrier, ring gear, thrust washers, circlips, and any carrier bearings/seals.
6. Pre-assembly preparations
6.1 Clean housing bores and apply light coat of gear oil to bearings and shafts.
6.2 Replace all seals, O-rings and any soft components.
6.3 Replace all fasteners with new if torque-to-yield or per service manual.
7. Install new planetary gear set
7.1 Fit new planet bearings/bushings onto planet pins; press-in if required.
7.2 Assemble planet gears onto carrier: place thrust washers where required, fit planets, install circlips to retain pins.
7.3 Fit sun gear and engage planets; place ring gear onto carrier or housing per design.
7.4 Press carrier bearings onto carrier if removed—use press with soft jaws and push on bearing outer race, avoid pressing on inner race through small shaft.
7.5 Install carrier assembly into case.
Tool use notes:
- Seal driver: install seals flush with housing; drive straight to avoid cocking.
- Press: when pressing bearings on a shaft, support inner race and apply force to inner race; when pressing bearings into bore, apply force to outer race.
8. Set gear backlash and bearing preload
8.1 Set carrier shims (if applicable) to achieve specified backlash between ring & sun gear. Use dial indicator to measure backlash: lock housing, mount indicator on carrier, rotate sun gear to see tooth runout/backlash, adjust shims until within spec.
8.2 Check bearing preload by measuring torque to turn assembled carrier or by checking axial endplay per manual. Add or remove shims as required.
8.3 Use Plastigage only where specified (e.g., checking bearing clearances). Do not rely solely on eyeballing.
8.4 Re-check rotation: smooth rotation with consistent torque and no binding. Recheck backlash after preload adjustment.
Important: Consult land-rover workshop manual for the exact backlash and preload specs. Incorrect preload or backlash will cause premature failure and noise.
9. Reassemble remaining components
9.1 Refit shafts, circlips, seals, and covers.
9.2 Replace gaskets or apply specified sealant (Loctite 518 where directed). Torque all bolts to OEM spec.
9.3 Reinstall oil pump (if removed), filters (if any), and final covers.
10. Refit transfer case to vehicle
10.1 Clean mating surfaces. Use new gasket/sealant as called for.
10.2 Lift case into position with transmission jack, align input shaft carefully into transmission/output.
10.3 Reinstall and torque case-to-transmission bolts to spec; reconnect driveshaft(s), sensors, linkages, and wiring.
10.4 Refill with correct grade and quantity of transfer case fluid/gear oil. Run engine and cycle through engagement to distribute oil.
11. Test & break-in
11.1 Start vehicle, check for leaks and abnormal noises at idle and during low-speed drives.
11.2 Road test under varied loads; listen for gear whine or vibration. Recheck fluid level after warm-up and again after break-in miles.
11.3 Re-torque external bolts after initial test drive if required by manual.
Common pitfalls & how to avoid them
- Reusing worn bearings or seals: always replace bearings & seals when accessible. Old bearings can destroy new gears.
- Incorrect shim/backlash adjustment: don’t guess—use a dial indicator and the correct shimming procedure. Wrong backlash = noisy or destroyed gearset.
- Improper bearing preload: must be set per spec. Too tight causes overheating; too loose causes noise and premature wear.
- Contamination: keep components clean; protect open housings and use lint-free rags. Dirt in gear teeth destroys surfaces quickly.
- Wrong assembly orientation: mark parts on disassembly (paint/marker) and photograph. Planet carriers and shafts often have specific orientations.
- Using excessive force: don’t hammer bearings in; use press or correct driver. Hitting bearings distorts races.
- Not replacing related parts: if bearings, races, or seals show wear, replace them. A new planetary set on old bearings is a short-term fix.
- Missing torque specs or reusing torque-to-yield bolts: use new bolts where specified and correct torque values.
Replacement parts checklist (typical)
- Planetary gear kit (sun, planets, carrier, ring) — matched set preferred.
- Planet bearings or bushings, planet pin circlips.
- Carrier bearings & races (if required).
- Thrust washers/shims and shim kit for backlash/axial play.
- Seals, O-rings, gaskets, bolts (as per manual).
- Transfer case/gear oil (volume & spec per manual).
- Loctite/RTV as specified.
Final notes
- Always work to the Land Rover/Freelander workshop manual for vehicle-specific disassembly order, torque values, shim data and clearances.
- If you are not experienced with setting gear backlash and bearing preload, have the assembly checked by a gearbox specialist — incorrect settings ruin new parts quickly.
End.
rteeqp73
- Vehicle jack + 4 jack stands or full two-post lift. Transmission jack or heavy-duty floor jack with wood block.
- Engine support bar or engine hoist (if required to lower gearbox).
- 1/4", 3/8", 1/2" drive socket sets (metric), long extensions, universal joints.
- Torx, hex/allen, and spline/OE driver set (as applicable).
- Impact wrench and breaker bar.
- Torque wrench (range to at least 200 Nm).
- Oil drain pan, funnels, rags, brake cleaner/parts solvent.
- Snap-ring pliers (internal & external).
- Bearing puller / three-jaw puller.
- Hydraulic or arbor press (or bench press) and soft jaws.
- Drift punches, brass/nylon punch, soft mallet.
- Seal puller and seal driver set.
- Circlip pliers, punches, small pry bars.
- Dial indicator with magnetic base (for backlash).
- Micrometer or calipers (for shim thickness, gear tooth thickness).
- Plastigage (optional, for clearances).
- Clean bench, parts trays, marking pen/paint.
- New transfer case/gearbox oil and sealant (Loctite 518 or OEM gasket if required).
- New replacement parts: planetary gear set (sun gear, planets, carrier, ring gear as a set or matched kit), planet bearings/bushes, thrust washers, carrier bearings, seals, O-rings, circlips, shims, fasteners (often replace bolts). Also consider replacement bearings in adjacent assemblies if worn.
- Workshop manual for vehicle-specific torque/specs and shim/backlash targets.
Safety precautions
- Work on level ground, use jack stands — never rely on a jack alone.
- Disconnect battery before starting.
- Support engine or transmission correctly; transfer cases are heavy—use a transmission jack.
- Wear safety glasses, gloves, protective footwear.
- Keep work area clean; do not allow dirt into gearsets.
- Use correct lifting technique and team-lift heavy parts.
- Mark orientation of components and take photos/notes during disassembly to ensure correct reassembly.
Overview (what you’re doing)
- Remove the transfer case / gearbox from the vehicle, disassemble to access planetary assembly, remove the old planetary set & bearings, press-in/install new gears/bearings, set correct shim/backlash and bearing preload, reassemble, refill fluids, test.
Step-by-step workshop procedure
1. Prepare vehicle
1.1 Park on level surface, chock wheels, disconnect negative battery.
1.2 Lift vehicle on hoist or raise and support on jack stands. Remove protective skid plates as needed.
1.3 Drain transfer case/gearbox fluid into pan; replace drain plug.
2. Remove transfer case / remove from vehicle
2.1 Support transmission/transfer case with transmission jack.
2.2 Unbolt propshaft(s)/driveshafts from transfer case flanges; tag and hang driveshafts aside.
2.3 Disconnect electrical connectors (sensors, switch), vacuum/pneumatic lines, linkage, and any cooling lines.
2.4 Unbolt transfer case-to-transmission (or adaptor housing) bolts. Support both sides to avoid stress.
2.5 Lower transfer case assembly carefully and remove to clean bench.
3. Strip external parts and prepare for disassembly
3.1 Clean exterior to reduce contamination upon opening.
3.2 Remove external covers, oil pump (if fitted), selector forks/covers as per manual.
3.3 Keep fasteners organized and labelled.
4. Disassemble transfer case to access planetary assembly
4.1 Remove snap rings/circlips retaining shafts and carriers using snap-ring pliers.
4.2 Pull out input/output shafts carefully; use puller if required. Mark orientation.
4.3 Remove carrier bolts and withdraw planet carrier assembly. Use press or gentle tapping as required.
4.4 Remove ring gear if separate; some units are integral to housing—follow manual.
4.5 Inspect bearings, bushings, thrust washers, and seals as you remove parts.
Tool use notes:
- Bearing puller: position puller evenly on bearing inner race and pull with steady pressure. Use backing plate under gearbox housing to avoid distorting housing.
- Press: use correct adapters and support carrier to press out bearings; apply steady pressure not shock. Warm bearings/housings slightly (oil bath) to ease fit if permitted by manual.
- Snap-ring pliers: compress ring fully before attempting removal to avoid deformation.
5. Inspect removed parts
5.1 Clean parts in solvent and inspect gear teeth for pitting, wear, or chipped teeth.
5.2 Measure bearings for play; check races for scoring.
5.3 If any bearing or race shows wear, replace. Planetary gears should be replaced as a matched set (sun/planet/ring) to preserve tooth profile.
5.4 Confirm replacement kit contents: planet gears, planet pins/shafts, planet bearings/bushings, sun gear, carrier, ring gear, thrust washers, circlips, and any carrier bearings/seals.
6. Pre-assembly preparations
6.1 Clean housing bores and apply light coat of gear oil to bearings and shafts.
6.2 Replace all seals, O-rings and any soft components.
6.3 Replace all fasteners with new if torque-to-yield or per service manual.
7. Install new planetary gear set
7.1 Fit new planet bearings/bushings onto planet pins; press-in if required.
7.2 Assemble planet gears onto carrier: place thrust washers where required, fit planets, install circlips to retain pins.
7.3 Fit sun gear and engage planets; place ring gear onto carrier or housing per design.
7.4 Press carrier bearings onto carrier if removed—use press with soft jaws and push on bearing outer race, avoid pressing on inner race through small shaft.
7.5 Install carrier assembly into case.
Tool use notes:
- Seal driver: install seals flush with housing; drive straight to avoid cocking.
- Press: when pressing bearings on a shaft, support inner race and apply force to inner race; when pressing bearings into bore, apply force to outer race.
8. Set gear backlash and bearing preload
8.1 Set carrier shims (if applicable) to achieve specified backlash between ring & sun gear. Use dial indicator to measure backlash: lock housing, mount indicator on carrier, rotate sun gear to see tooth runout/backlash, adjust shims until within spec.
8.2 Check bearing preload by measuring torque to turn assembled carrier or by checking axial endplay per manual. Add or remove shims as required.
8.3 Use Plastigage only where specified (e.g., checking bearing clearances). Do not rely solely on eyeballing.
8.4 Re-check rotation: smooth rotation with consistent torque and no binding. Recheck backlash after preload adjustment.
Important: Consult land-rover workshop manual for the exact backlash and preload specs. Incorrect preload or backlash will cause premature failure and noise.
9. Reassemble remaining components
9.1 Refit shafts, circlips, seals, and covers.
9.2 Replace gaskets or apply specified sealant (Loctite 518 where directed). Torque all bolts to OEM spec.
9.3 Reinstall oil pump (if removed), filters (if any), and final covers.
10. Refit transfer case to vehicle
10.1 Clean mating surfaces. Use new gasket/sealant as called for.
10.2 Lift case into position with transmission jack, align input shaft carefully into transmission/output.
10.3 Reinstall and torque case-to-transmission bolts to spec; reconnect driveshaft(s), sensors, linkages, and wiring.
10.4 Refill with correct grade and quantity of transfer case fluid/gear oil. Run engine and cycle through engagement to distribute oil.
11. Test & break-in
11.1 Start vehicle, check for leaks and abnormal noises at idle and during low-speed drives.
11.2 Road test under varied loads; listen for gear whine or vibration. Recheck fluid level after warm-up and again after break-in miles.
11.3 Re-torque external bolts after initial test drive if required by manual.
Common pitfalls & how to avoid them
- Reusing worn bearings or seals: always replace bearings & seals when accessible. Old bearings can destroy new gears.
- Incorrect shim/backlash adjustment: don’t guess—use a dial indicator and the correct shimming procedure. Wrong backlash = noisy or destroyed gearset.
- Improper bearing preload: must be set per spec. Too tight causes overheating; too loose causes noise and premature wear.
- Contamination: keep components clean; protect open housings and use lint-free rags. Dirt in gear teeth destroys surfaces quickly.
- Wrong assembly orientation: mark parts on disassembly (paint/marker) and photograph. Planet carriers and shafts often have specific orientations.
- Using excessive force: don’t hammer bearings in; use press or correct driver. Hitting bearings distorts races.
- Not replacing related parts: if bearings, races, or seals show wear, replace them. A new planetary set on old bearings is a short-term fix.
- Missing torque specs or reusing torque-to-yield bolts: use new bolts where specified and correct torque values.
Replacement parts checklist (typical)
- Planetary gear kit (sun, planets, carrier, ring) — matched set preferred.
- Planet bearings or bushings, planet pin circlips.
- Carrier bearings & races (if required).
- Thrust washers/shims and shim kit for backlash/axial play.
- Seals, O-rings, gaskets, bolts (as per manual).
- Transfer case/gear oil (volume & spec per manual).
- Loctite/RTV as specified.
Final notes
- Always work to the Land Rover/Freelander workshop manual for vehicle-specific disassembly order, torque values, shim data and clearances.
- If you are not experienced with setting gear backlash and bearing preload, have the assembly checked by a gearbox specialist — incorrect settings ruin new parts quickly.
End.
rteeqp73
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