Gearbox PG1 — removal and installation (Freelander 1)

Dismantling

1. Disconnect the negative battery terminal.

2. Remove the battery.

ENGINE STARTING AND BATTERY CHARGING SYSTEM, REPAIR WORK, Battery.

3. Remove the starter.

ENGINE STARTING AND BATTERY CHARGING SYSTEM, REPAIR WORK, Starter - engine K1.8.

4. Disconnect the 2 fastening clamps from the battery platform. Unscrew the 4 fastening bolts of the battery platform and remove the platform.



6. Disconnect the reversing light switch connector.

7. Disconnect the connector from the first gear engagement contact sensor.

8. Disconnect the clamp securing the first gear contact sensor harness to the clutch slave cylinder bracket.

9. Unscrew the 3 bolts securing the slave cylinder bracket to the gearbox and secure the bracket to the side.



10. Remove the transfer case (IRD).

TRANSFER CASE, REPAIR WORK, Transfer case: models with K1.8 engine.

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11. Install the LRT-54-026 tool onto the drive shaft inner joint. Use a lever to release the left inner joint from the gearbox.



12. Remove and discard the left drive shaft inner joint snap ring.



13. Remove the gearshift rod pivot pin cover, remove and discard the pin.



14. Disconnect the gear shift rod from the gear selector rod.

15. Loosen the bolt securing the gearshift rod spacer to the transfer case bracket and remove the spacer from the bracket.



16. Unscrew the 2 bolts securing the engine sump to the gearbox.



17. Mark how the flat washer is installed and unscrew the M6 nut with the bolt securing the front cover to the gearbox.

18. Unscrew the upper front nut with the bolt securing the gearbox to the engine.

19. Unscrew the 2 front nuts with bolts securing the gearbox to the engine, remove the front cover.



20. Remove the bolt from the gearbox as shown in the figure and use this bolt to secure the lifting eye to the gearbox.



21. Attach the lifting equipment to the rigging eye.



22. Unscrew the through bolt securing the left engine support to the gearbox.

23. Lower the engine to gain access.



24. Unscrew the 2 bolts securing the left support to the gearbox and remove the support.

25. Support the engine by placing a jack with a wooden block as a spacer under the pan.



26. Note the position of the engine ground bus and remove the 2 upper gearbox-to-engine mounting bolts.



27. With the help of a partner, move the gearbox away from the 2 mounting pins. Lower the gearbox to the floor and remove the rigging from it.

Installation

1. Wipe the mating surfaces of the engine and gearbox, the pins and their seats.

2. Check the condition of the drive shaft seal and replace it if it is damaged or worn.

3. Lightly lubricate the input shaft splines with molybdenum disulfide grease.

4. Wipe and degrease the threaded parts of the two upper transmission-to-engine mounting bolts. Apply STC 50552 sealant to the threaded parts of both bolts.

5. Position the gearbox under the vehicle and attach the rigging to it.

6. With the help of a partner, lift the gearbox and slide it onto the pins.

7. Install the ground busbar in its place, screw in the two upper bolts securing the gearbox to the engine.

8. Install the front cover, screw in the bolts and tighten the nuts.

9. Tighten the upper bolts and front nuts and bolts to 80 Nm. Tighten the transmission-to-sump bolts to 45 Nm.

10. Place a flat washer on the M6 bolt, screw in the bolt, fit the nut and tighten to 9 Nm.

11. Remove the rigging from the gearbox.

12. Loosen the bolt securing the eye to the gearbox, remove the eye, screw the bolt back in place and tighten it to a torque of 45 Nm.

13. Install the left engine mount onto the gearbox, screw in the bolts and tighten them to 65 Nm.

14. Raise the gearbox and align the left engine mount with the mount bracket. Install the through bolt and tighten it to 80 Nm.

15. Remove the jack from under the engine.



16. Install the shift rod spacer, screw in the bolt and tighten it to 25 Nm.

17. Install the shift rod onto the selector rod, install the NEW pivot pin and replace the cover.

18. Wipe the splined portion of the drive shaft and the mating splines in the gearbox.

19. Install a new snap ring onto the end of the left drive shaft.

20. With the help of a partner, insert the left drive shaft into the gearbox, holding it at the correct angle to avoid damaging the gearbox seal.

21. Install the transfer case (IRD).

TRANSFER CASE, REPAIR WORK, Transfer case: models with K1.8 engine.

22. Install the clutch slave cylinder mounting bracket on the gearbox, screw in the bolts and tighten them to a torque of 25 Nm.

23. Connect the connector to the first gear contact sensor and secure the harness with a clamp to the slave cylinder bracket.

24. Connect the reversing light switch connector.

25. Replace the battery tray and tighten the mounting bolts to 10 Nm.

26. Secure the wiring harness with clamps to the battery tray bracket.

27. Reinstall the starter.

ENGINE STARTING AND BATTERY CHARGING SYSTEM, REPAIR WORK, Starter - engine K1.8.

28. Install the battery.

ENGINE STARTING AND BATTERY CHARGING SYSTEM, REPAIR WORK, Battery.

29. Connect the negative battery terminal.