DisclaimerLand Rover Range Rover Technical Service Bulletin # TECLM204007 Date: 060912

Wheels/Tires - Steering Wheel Vibration

No: LM204-007

Issue: 1

Date: 12 Sep 2006

THIS BULLETIN REPLACES TECHNICAL BULLETIN 60/02/03/NAS

SECTION: 204-04 WHEELS AND TIRES

Steering Wheel Vibration

AFFECTED VEHICLE RANGE:

Range Rover (LM)

VIN:

ALL

CONDITION SUMMARY:

STEERING VIBRATION FROM TIRE FLAT-SPOTTING AND RADIAL FORCE VARIATION

Situation:

This bulletin addresses concerns of a steering wheel vibration/steering shimmy identified on the initial vehicle preparation road test or from a

customer complaint. Tire flat-spots are a likely cause.

A customer may also complain of steering vibration or "shimmy" at moderate highway speeds (55mph). Sources of vibration/shimmy can be an

out-of-balance condition or Radial Force Variation (RFV) in the wheel-tire assemblies. Also the positioning/mounting of the wheels on the vehicle

can be a factor.

Action:

Carry out the Repair Procedure to correctly diagnose tire flat-spots and wheel balancing requirements.

In case of a customer complaint of vibration/shimmy on vehicles, follow the optimization procedures in this bulletin using a Hunter 9700/9712

balancing machine.

PARTS:

NOTE:

Correct two-part wheel weights are available from Wurth USA (800 987 8487). Wurth part numbers are provided below for information:

237

Locally Sourced WURTH weight numbers:

TOOLS:

Hunter 970019712 wheel balance machine

To ensure that the wheel/tire assembly is balanced correctly, Land Rover recommends the use of a five fingered clamp to support the wheel and tire

assembly on the balance machine. (Figure 1)

Haweka 9700 hub to wheel adapter (Figure 2)

WARRANTY:

NOTE:

Repair procedures are under constant review, and therefore times are subject to change; those quoted here must be taken as guidance only.

Always refer to DDW to obtain the latest repair time.

NOTE:

Steps 1 to 5 of the procedure are part of the Vehicle Preparation process. No claim should be initiated if the performance of these steps at initial

vehicle preparation resolves the concern.

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DDW requires the use of causal part numbers.

Labor only claims must show the causal part number with a quantity of zero.

Normal warranty policy and procedures apply.

REPAIR PROCEDURE

VEHICLE PREPARATION STEPS

NOTE:

Step 1 of the procedure is part of the Vehicle Preparation process. No claim should be initiated if the performance of this step at initial vehicle

preparation resolves the concern.

NOTE:

Until flat-spots are removed, significant shimmy may be present, even if the car has only stood overnight. A test drive is required to ensure

temporary tire flat spots are removed. For longer term flat-spots, a longer drive may be required. The test drive should be carried out on normal

open roads to allow the highest speed that speed limits and road/traffic conditions allow.

1. If the vehicle is undergoing initial vehicle preparation, perform the following as part of the test drive:

^ Refer to the Vehicle Preparation Manual and adjust the tire pressures to the recommended cold tire pressures.

^ Drive the vehicle for at least 15km (10 miles) before attempting to assess shimmy.

^ Assess the level of wheel vibration.

2. If a customer complaint is being resolved, perform the following:

^ Adjust the tire pressures to the recommended cold tire pressures.

^ Drive the vehicle for at least 15km (10 miles) before attempting to assess shimmy.

^ Assess the level of wheel vibration.

3. If the level of steering vibration is considered acceptable, no further action is required.

4. If the levels of vibration remain unacceptable, perform the "Balance Wheels" section below.

BALANCE WHEELS AS REQUIRED

1. Raise vehicle on the lift immediately on returning to the workshop, to avoid inducing further tire flat spots.

2. Remove all four road wheel and tire assemblies for balancing.

3. Inflate each tire to 2.5bar (36lbf/sq.in) +/- 0.1 bar (1lbft/sq.in).

NOTE:

For adhesive weights, use the attachment arm on the Hunter machine to ensure accurate weight positioning.

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4. Refer to Figures 3, 4 and 5 for correct wheel fitting attachment to the balance machine and balance road wheel and tire assemblies until the

residual imbalance dynamic is minimized.

^ Target is 0g on each plane, maximum is inner 5g, outer 5g.

^ Use the "bulls-eye" balancing mode to minimize residual imbalance.

5. If tire road force variations (RFV) measuring is available, the road wheel and tire assembly should aim for a maximum of 60 Newton (6.1 kgf /

13.4 lbf) first harmonic RFV, 100 Newton (10.2 kgf/22.5 lbf) peak-to-peak.

6. If these levels cannot be achieved, perform the following:

^ Remove the tire.

^ Follow the match mounting procedure as detailed by the Hunter machine.

^ Mark the high point of 1st harmonic RFV on the tire (ideally also mark on the inside too, as a future reference).

^ Install the lowest 1st harmonic RFV units to the front.

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^ Print out the results of balance and force variation before and after, and attach to repair order.

NOTE:

If RFV equipment is not available and the tire has not been removed from the wheel and the RFV spot (red dot) is still visible this, should

be installed at the top.

7. The high-point of RFV should be marked, and the road wheel and tire assembly installed to the vehicle with the RFV high point at the top,

prior to the wheels being tightened. (Figure 6)

NOTE:

Nothing should be used to brace the wheel while tightening the nuts as this can disturb the match mounting.

8. Install all four road wheel and tire assemblies.

9. Tighten wheel nuts to 140Nm (103 lbf ft).

10. Lower the vehicle onto the lift.

11. Restore tire pressures to the recommended settings.

12. Drive the vehicle for approximately 7km (5 miles) carried out on normal roads and up to speeds of approximately 80 km/h (50 mph) to verify

correction of steering vibration.

DisclaimerLand Rover Range Rover Technical Service Bulletin # TEC7612032 Date: 060104

Body - Front/Rear Door Difficult to Open

No: 76/12/03/NAS

Ref:

*Issue: 2*

*Date: January 4, 2006*

Difficult Door Latch Operation

Updated information is shown with asterisks.

AFFECTED VEHICLE RANGE:

*Range Rover (LM) ALL*

SITUATION:

FRONT AND/OR REAR DOOR DIFFICULT TO OPEN

The customer may complain that extra effort is required to operate the front or rear door latches. Free play in the door latch release cable may be the

cause of this complaint.

RESOLUTION:

ADJUST DOOR LATCH *ADJUSTER* SCREWS

When the above complaint is verified, perform the adjustment procedure in this TIB to improve the ease with which the doors may be opened.

PARTS INFORMATION:

No Parts Required

WARRANTY CLAIMS

REPAIR PROCEDURE

DOOR LOCK ADJUSTMENT

1. Open front and rear doors.

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2. Remove the grommet from the front doors (Figure 1) and the rear doors (Figure 2) for access to the door lock *adjuster* screw.

CAUTION:

The screw threads are counter-clockwise on LH doors and clockwise on RH doors.

3. Release the door lock *adjuster* screw on the affected door(s) two turns.

4. Tighten the door lock *adjuster* screws to 4 Nm (36 lbf.in.).

5. Install the door lock *adjuster* screw grommets.

6. Close front and rear doors.

DisclaimerLand Rover Range Rover Technical Service Bulletin # TEC7610036 Date: 060605

Body - Various Wind Noise Concerns

No: 76/10/03/NAS

*Issue: 6

Date: 05 June 2006*

Wind Noise Corrective Actions

*CHANGES MADE FOR ISSUE "6" ARE HIGHLIGHTED WITH GREY BACKGROUND AND NOTED BY ASTERISKS*.

AFFECTED VEHICLE RANGE:

241

New Range Rover (LM)

See Individual Repairs

SITUATION

VARIOUS WIND NOISE LOCATIONS MAY REQUIRE CORRECTIVE ACTION

The customer may complain of wind noise appearing to come from a variety of locations:

* High pitched hiss or buzzing from the windshield

* Noise from the top of the windshield

* Whistle from front of vehicle when driven at highway speeds

* Hiss or leaking sound from A-pillar and side mirror area (above 40 mph (65 kph))

* Buzzing sound from central area of headliner or rear of vehicle

* High level noise from A-pillar area

RESOLUTION:

PERFORM INDIVIDUAL REPAIR PROCESSES FOR EACH SYMPTOM

Each of the specific problem areas has a unique repair to resolve the noise complaint. After investigation to determine the source of the sound,

perform the repair specific to that area.

PARTS INFORMATION:

Repair 1..........A HIGH-PITCHED HISS FROM THE WINDSHIELD

No parts required

Repair 2..........BUZZING FROM THE WINDSHIELD AT HIGHWAY SPEEDS

Polyurethane Sealant - Locally sourced

Repair 3..........NOISE FROM THE TOP CORNERS OF THE WINDSHIELD

No parts required

Repair 4..........HIGH-PITCHED WHISTLE NOISE FROM THE FRONT OF THE VEHICLE

XCH500020..........Rubber strip Qty 2 per vehicle

Repair 5..........HISS OR LEAKAGE NOISE AROUND THE 'A' PILLAR AND DOOR MIRROR

CTT500020..........Foam Pad Qty 2 per vehicle

Polyurethane Sealant - Locally sourced

Repair 6..........BUZZING SOUND FROM CENTER OF HEADLINER OR REAR OF VEHICLE

Polyurethane Sealant - Locally sourced

Repair 7..........HIGH LEVEL OF WIND NOISE FROM 'A' PILLAR AREA

79086L..........Black expanding clip Qty 8

DYA000040..........Grommet Qty 8

DYC500020..........Yellow clip Qty 8

Repair 8..........HISSING/FLUTTERING NOISE FROM THE REAR DOOR FIXED SIDE GLASS

Polyurethane Sealant - Locally sourced

*Repair 9..........WHISTLE NOISE FROM CENTER OF WINDSHIELD AT HIGHWAY SPEEDS

* MWC9832PMA..........Fir-tree fastener Qty 1*

Repairs 10 - 13..........VARIOUS WIND NOISES No parts required.

WARRANTY CLAIMS:

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Normal warranty policy and procedures apply. Material allowance is included in labor operation.

REPAIR PROCEDURE

REPAIR 1: ALL VEHICLES

A gap between the windshield trim and the roof causes a high-pitched hiss from the windshield at approximately 38 - 50mph (60-80km/h).

CAUTION:

The top trim piece of the windshield must be protected to prevent damage. A gap must not be created between the bottom edge of the trim strip

and the windshield.

1. Using a nylon block and rubber mallet, move the windshield top trim upwards to close the gap. (Figure 1, Inset A)

2. Align trim to the roof until a "touch" condition is achieved along the entire length of the trim. (Figure 1, Inset B)

REPAIR 2: ALL VEHICLES

A gap or bulge between the windshield lower trim piece and the windshield causes a buzzing from the windshield area at highway speeds.

1. Lift wipers away from the windshield for access.

2. Clean the windshield at the junction with the plenum seal along the entire length of the plenum seal.

243

3. Filling all gaps completely, apply polyurethane sealant between the seal and the windshield along the entire length of the seal. (Figure 2)

4. Remove any excess sealant.

5. Position wipers onto the windshield.

REPAIR 3: ALL VEHICLES

A gap between the windshield and the roof molding causes noise from the top corners of the windshield. (Figure 3, Inset A)

NOTE: The roof molding must be set in the correct fore/aft position to achieve a flush fit.

NOTE: GTR lookup sequence is as follows: GTR Home > NAS > Service Information/ LM - New Range Rover/2003 (or as applicable)>

Workshop Manuals > Service Procedures > Bookmark "76-2 - Exterior Fittings (or as applicable)" Link "76.43.68 Roof Moulding (or as

applicable)"

1. Refer to GTR Workshop Manual section 76-2 - Exterior Fittings procedure 76.43.68 and remove the roof molding.

2. Install the molding, aligning the rear end of the molding with the rear edge of the roof.

REPAIR 4: UP TO VIN 3A106721

A gap between the direction indicator lamp and the fender causes a high-pitched whistle noise from the front of the vehicle at high speeds.

1. Refer to GTR Workshop Manual section 86-2 - Lighting procedure 86.40.29 and remove the Left Hand and Right Hand front directional lamp

assemblies.

2. Clean the fender area where the adhesive strip will be applied. (Figure 4)

3. Remove protective backing from the adhesive rubber strip and secure to the fender. (Figure 4)

4. Install directional assemblies.

REPAIR 5:* UP TO VIN 4A152789*

A noise path between the mirror and the 'A' pillar causes a hiss or leakage noise from around the 'A' pillar and door mirror area at speeds greater than

40mph (64km/h).

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NOTE: Noise may be present even if NO gap exists.

1. Lower both front windows.

2. Ease out approximately 200mm (8 inches) of the window channel seal to expose the door seal channel. (Arrowed in Figure 5)

CAUTION:

The foam must extend equidistant to either side of the angle and must not overhang on either side of the seal.

3. Center the foam (CTT500020) on the angle in the seal and stick it onto the back of the seal directly over the angle. (Shaded in Figure 6)

4. Carefully fit the window channel seal to the door.

5. Repeat for the opposite side.

6. Refer to Technical Information Bulletin 76/18/03/NAS and verify that the window 'one touch' mode is operating correctly.

7. If the window 'one touch' mode is NOT operating correctly, complete the following steps:

* Remove the 200mm (8 inches) of the window seal again to expose the seal channel. (Arrowed in Figure 5)

* Remove the foam pad inserted above.

* Wipe the surface surrounding the joint with alcohol. (Figure 7)

NOTE: The outer most corner of the joint must be completely sealed with sealant.

* Apply a small amount of sealant into the base of the angle and push the sealant firmly into the back of the channel. (Inset in Figure 7)

* Apply sealant until it starts to protrude from the hole at the top of the cheater panel.

* Wipe off excess sealant.

* Install the glass seal to the door.

8. Refer to Technical Information Bulletin 76/18/03/NAS and verify that the window 'one touch' mode is operating correctly.

REPAIR 6: *UP TO VIN 3A131067*

A gap between the 'E' pillar seal and the quarter glass can result in a buzzing sound from the rear of vehicle or center of the headlining.

1. Refer to GTR Workshop Manual section 76-2 - Exterior Fittings procedure 76.43.36 and remove the 'E' pillar trim.

2. Clean quarter glass and 'E' pillar trim.

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3. Apply a 2mm (3/32 in.) bead of sealant along the entire forward edge of the 'E' pillar trim seal. (Arrowed in Figure 8)

4. Carefully install the 'E' pillar trim.

5. Remove excess sealant from 'E' pillar trim seal and the quarter glass. (Figure 9)

6. Repeat procedure for the alternate side.

REPAIR 7: UP TO VIN 3A114820

A gap between the side trim and windshield or a rocking / loose side trim may result in a high level of wind noise from 'A' pillar area at highway

speeds.

NOTE: The noise is most likely due to the side trim having been previously removed for windshield replacement.

1. Refer to GTR Workshop Manual section 76-2-Exterior Fittings procedure 76.43.39 and remove the 'A' pillar windshield side trim.

2. Remove and discard the black clips from the trim and retaining inserts from the 'A' pillar. (Arrowed in Figure 10)

3. Install new yellow clips (DYC500020) to secure the trim to the front of the 'A' pillar.

4. Install new retaining inserts (DYA000040) into the 'A' pillar.

5. Install new expanding clips (79086L) into the trim piece.

6. Position the trim to the front of the 'A' pillar and secure using expanding clips.

REPAIR 8: *ALL VEHICLES*

The rear door fixed side glass is not sufficiently bonded to the door *or gaps* are present in the *bonding* causing a *hissing or fluttering* noise

from the top rear corner of the fixed door glass.

* 1. Apply tape around the interior perimeter of the fixed side door glass, ensuring a sufficient seal between the glass and surround molding, to

246

confirm the cause of the noise during a road test.

2. Remove the tape from the side door glass.

3. Refer to GTR Workshop Manual section 76-1 - Doors procedure 76.34.04 and remove the rear door trim casing for access.

4. Remove the fixed side glass surround trim.

5. Remove interior waist seal. (Figure 11)

NOTE: For the fixed side glass to be correctly bonded, all Body-In-White (BIW) clips around the periphery of the glass must be completely

covered by the bonding material. The bonding is not correct if there are any gaps in the bonding or if any BIW clips are visible. (Figure 12)

6. Visually inspect for correct bonding around the perimeter of the fixed side door glass. (Figure 13)

7. If the bonding material around the perimeter of the glass has any gaps or does not completely cover all Body-In-White (BIW) clips, apply

sufficient Polyurethane Sealant to fill any gaps and completely cover all BIW clips, ensuring that the sealant is hidden by the black band

around the glass edges.*

8. If the rear door fixed glass is not properly bonded, refer to GTR Workshop Manual section 76-1 - Doors procedure 76.31.31 and remove the

rear door fixed side glass.

9. Install the rear side door fixed glass following adhesive guidelines in the GTR Workshop Manual. (Figure 14)

REPAIR 9: ALL VEHICLES

A whistle noise is heard from the centre of the windshield at speeds in excess of 60mph (97km/h). The noise may be caused by airflow over the

247

passenger side plenum drain tube opening. The plenum drain tube opening is divided into four quadrants.

1. Tape over plenum drain tube opening to verify cause of the noise.

* 2. Remove tape after road test.

3. Insert Fir-tree fastener (MWC9832PMA) into the in-board, front quadrant of the drain tube opening. (Figure 15)*

REPAIR 10: ALL VEHICLES WITH SUNROOF

A general wind noise is heard from the front leading edge of the sunroof when traveling in excess of 50mph (80km/h). The likely cause is poor

sunroof alignment profile.

1. Tape the leading edge of the sunroof to verify cause of the noise.

2. Remove tape after road test.

NOTE: GTR lookup sequence is as follows:

GTR Home > NAS > Service Information/ LM - New Range Rover/2003 > Workshop Manuals > Range Rover - Workshop Manual - Service

Procedures > Bookmark "76-6 - Sunroof" > Link "76.84.82 Sunroof - align to roof panel & adjust"

3. Refer to GTR section 76.84.82 and perform sunroof adjustment and alignment to roof panel.

REPAIR 11: ALL VEHICLES

A whistle is heard from the lower windshield area at speeds in excess of 50mph (80km/h) only when the recirculation damper is shut. The noise is

likely to be caused by a trapped foot well lamp wire in the recirculation "snail shell" housing.

NOTE: In the event of a concern of a noise from behind the instrument panel when the Heating Ventilation Air Conditioning (HVAC) is in

recirculation or automatic mode, evident at road speeds of above 60mph (100km/h), refer to Technical Bulletin 82/01/05/NAS - Range Rover

(LM) - Noise From HVAC System.

1. Reproduce the complaint during a test drive and cycle in and out of recirculation mode to confirm the suspected cause of the complaint.

2. Remove the pollen filter to access snail shell housing and free the trapped wire. (Figure 16)

REPAIR 12: ALL VEHICLES

A general wind noise is heard from the top of the B-pillar area at speeds in excess of 30mph (48km/h). The noise may be caused by the front door

glass being set too far forward.

1. Close the affected window completely.

248

2. Determine if the top corner radius of the window glass, adjacent to the B-Pillar, is visible indicating that the window is set too far forward.

(Figure 17)

3. If the corner is not visible, use a blunt plastic implement to gently probe the top rear edge of the seal to assess the overlap of the seal over the

glass. (Figure 18)

4. If the glass can be felt, it is unlikely that improper window glass alignment is the cause of the complaint.

5. If the glass cannot be felt, lower the window by approximately 260mm (10 inches), to position window glass for access to the securing torx

bolts. (Figure 19)

NOTE: GTR lookup sequence is as follows: GTR Home > NAS > Service Information/ LM - New Range Rover/2003 > Workshop Manuals

> Range Rover - Workshop Manual - Service Procedures > Bookmark "76-1 Doors" > Link "76.34.01 Trim casing - front door"

6. Refer to GTR Workshop Manual section 76.34.01 and remove the front door casing for access only.

7. Partially release the plastic sheet and temporarily secure up and out of the way to gain access to torx bolts securing glass. (Figure 20)

NOTE: If attempts are made to move the glass rearwards without lifting the glass out of the clamps, the glass may return to original position

due to elasticity of the rubber clamps.

8. Loosen torx bolts securing glass.

9. Lift glass out of clamps and move glass rearward by the amount of the observed gap at initial inspection. (Figure 21)

249

10. Lower glass back into the clamps.

11. Secure front glass torx bolts to 10 Nm (7 lbf-ft).

12. Temporarily connect the harness to confirm operation of window glass and ensure window glass has been set correctly and can raise fully.

(Figure 22)

13. Install partially removed plastic sheet and verify that a good seal to the door panel has been achieved.

14. Refer to GTR Workshop Manual section 76.34.01 and install the front door casing.

15. Verify correct operation of door mounted switchpack and speakers after the door casing is installed.

REPAIR 13: ALL VEHICLES

A general wind noise and whistle from top of windshield at speeds in excess of 50mph (80km/h) may be heard. The noise could be caused by the

leading edge of the roof rail finisher lifting.

1. Unclip roof rail finisher, position the finisher correctly, and reinstall the clip. (Figure 23)

DisclaimerLand Rover Range Rover Technical Service Bulletin # TA057602 Date: 050610

Body - Carbalflo XTR5(R) Lubricant Usage

TA05 7602

June 10, 2005

Use of Carbaflo XTR5 for Range Rover (LM)

PDI and Scheduled Maintenance

Technical Information Bulletin 76/08/05/NAS introduced the use of Carbaflo XTR5, available under part number LRNXTR5, as a solution for the

squeaking noise sometimes generated by the top "flip-seal" on Range Rover doors. In addition to introducing the new lubricant, TIB 76/08/05/NAS

also more carefully defined the textured flip seal at the top of each door potentially affected by the problem.

That same flip seal should also be lubricated at each PDI and each Scheduled Maintenance Service as a preventative measure. The requirement to

apply a silicon spray lubricant on door flip seals has been replaced by the use of Carbaflo. All Maintenance and PDI Schedules relating to Range

Rover (LM) have been updated on InfoTrail to reflect the use of the newly introduced lubricant. Changes to PDI and Complimentary Scheduled

Maintenance Program reimbursement are being made to compensate for the cost of this special lubricant application.

38

To ensure that all Retailers are aware of the change to the PDI and Maintenance Schedules, and to confirm the precise seal to be lubricated please

review the illustration and the information in TIB 76/08/05/NAS found on GTR.

DisclaimerLand Rover Range Rover Technical Service Bulletin # TEC570505 Date: 050412

Steering - Steering Column Reach Motor Noise

No: 57/05/05/NAS

FGN LM211

Ref:

190

Issue: 1

Date: 12 April 2005

Steering Column Reach Motor Noise

AFFECTED VEHICLE RANGE:

New Range Rover (LM) All

SITUATION:

NOISE FROM MECHANISM DURING REACH ADJUSTMENT

NOTE:

Reach mechanism "jamming" will generally be the result of improper lubrication. Refer to TIB 57/04/05/NA5 for guidance on the lubrication

only procedure associated with reach mechanism jamming.

The customer may complain that during reach adjustment a noise is evident from the steering column during the adjustment motion.

RESOLUTION:

STEERING REACH MOTOR REPLACEMENT

Upon customer complain of the noise symptoms during reach adjustment, follow the Repair Procedure outlined in this bulletin to install a reach

motor kit. If it is determined during troubleshooting that the reach motor has electrical faults this procedure may also be followed.

PARTS INFORMATION:

NOTE:

There is no requirement to replace anything other that the motor to repair a reach mechanism adjustment noise condition or an reach motor

electrical fault. The steering column assembly is not required.

DDW WARRANTY CLAIMS:

DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.

Normal warranty policy and procedures apply.

Material allowance is included in labor operation.

REPAIR PROCEDURE

REPLACE REACH MOTOR

NOTE:

GTR lookup sequence is as follows:

GTR Home > NAS > Service Information/ LM Range

Rover/2005 > Workshop Manuals > Service

Procedures > Bookmark "STEERING/REPAIRS" >

link "Column assembly - inner & outer"

1. Refer to GTR Workshop Manual section 57.40.01 and remove the steering column assembly.

191

2. Release and remove the reach motor from the steering column. (Figure 1)

NOTE:

Broken plastic motor clips may be found upon disassembly or may occur during motor removal. Broken clips will be replaced later in the

procedure.

3. If the plastic motor clip is unbroken, leave it in position.

4. Remove the flexible drive from the steering column.

5. Refer to the steering column bar code label (Figure 2) and determine if the column number is before or after column number "73067" (Week

Number 44 Year 03)

6. If the column number is before "73067" perform the following:

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^ Insert the special tool, part number QME500100, into the square drive of the spindle. (Figure 3)

^ Hold the shaft with the tool and release the spindle nut half a turn. (Figure 4)

^ Hold the shaft with the tool and tighten the spindle nut to 6Nm (4.5 lbf.ft). (Figure 5)

193

^ Hold the shaft with the tool and release the spindle nut one "flat." (Figure 6)

^ Remove the tool.

7. If the plastic motor clip is broken, or breaks during motor removal, perform the following:

^ Remove the broken clip by levering it off. (Figure 7)

CAUTION:

It is critical that the plastic clip is fully engaged into the steering column aluminum body. There will be a loud snapping noise as the clip

engages.

^ Align the key on the new plastic motor retaining clip with the machined slot on the aluminum body of the column

^ Snap the new clip into position.

^ Verify that the key is located in the slot and the clip is securely located.

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8. Insert the flexible drive into the spindle. (Figure 8)

9. Slide the new motor fully back into the plastic clip, guiding the flexible drive into the gearbox.

10. Verify that the peg locates fully into the motor and that the motor is correctly located in the clip. (Figure 9)

11. Apply a thin bead of grease onto the tilt and reach

12. Refer to GTR Workshop Manual section 57.40.01 and install the steering column assembly.

DisclaimerLand Rover Range Rover Technical Service Bulletin # TA004402 Date: 001122

Recall - A/T Breather Hose Repositioning

TA00 4402

195

November 22, 2000

ATTENTION:

General Manager

Sales Manager

Service Manager

Service Advisor

Technician

AT Breather Repositioning and Fluid Check

IMPORTANT NOTE:

This Technical Alert supersedes and replaced TA00 4401

NOTE: The Service Action described in this Technical Alert is required due to a safety defect notification made by Land Rover North America to

NHTSA. Ensure that this Technical Alert is routed immediately to all of the persons in the "ATTENTION" distribution.

Land Rover North America will be issuing a Safety Recall for vehicles in service that are within the affected VIN range. Appropriate notices will be

mailed to all owners once the recall procedures are developed and verified for in-service vehicles.

VEHICLES WITHIN THE AFFECTED VIN RANGE THAT ARE IN RETAILER STOCK MUST BE MODIFIED PRIOR TO SALE.

This Service Action is to be executed on all affected new and used vehicles in Retailer inventory prior to delivery.

The Repair 1 procedural steps only apply to undelivered vehicles which have not been deep water waded, which do not have a warranty start date

activated and have less than 500 miles on the odometer.

The Repair 2 procedural steps apply to new and used vehicles in retailer inventory which have in excess of 500 miles on the odometer.

NOTE:

Used vehicles within the VIN range in retailer inventory, INCLUDING DEMOS WITH AN ACTIVE WARRANTY DATE, must pass the AT

fluid test outlined below. Vehicles that fail the visibility test may not be retailed until the Recall bulletin for vehicles with accumulated mileage

has been issued.

No action is to be taken on vehicles that have been delivered to customers. Delivered vehicles will be addressed by the Recall bulletin where

additional procedures will be outlined.

AFFECTED VEHICLE RANGE:

Range Rover (LP) XA410504 to 1A449412

Discovery Series II (LT) XA200000 to 1A299999

XA900000 to XA907212

1A700000 to 1A706116

SITUATION:

TRANSMISSION WATER INGRESS THROUGH BREATHER

Condensation from Air Conditioning and water from a "deep wading" event can flow over the transmission and collect on the transmission breather

tube on Range Rover and Discovery Series II vehicles. It can then migrate up the transmission tube. Over time these small water droplets can cause

an accumulation of water in the transmission causing problems associated with water contamination - harsh gear changes, poor gear selection, gear

slip or loss of drive and intermittent failure of the park lock function. Inspections and resolution for these faults will be addressed by the formal

Recall.

RESOLUTION:

REPAIR 1: REPOSITION BREATHER TUBE AT PDI - NEW VEHICLES UP TO 500 MILES

At or before delivery of a vehicle to a purchaser, re-route the breather tube to the top of the transmission to eliminate the breather tube as a source of

transmission contamination.

REPAIR 2: REPOSITION BREATHER TUBE AND INSPECT FLUID - NEW AND USED VEHICLES OVER 500 MILES

At or before delivery of a vehicle to a purchaser test the AT fluid as outlined in the Procedure section of the Alert. If the AT fluid is found to be

uncontaminated by the test, re-route the breather tube to the top of the transmission to eliminate the breather tube as a source of transmission

contamination.

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PARTS INFORMATION:

WARRANTY CLAIMS:

REPAIR PROCEDURE

CAUTION:

No vehicle that has been waded, or has been delivered to a customer is to be corrected following the breather hose positioning procedure ONLY.

Additional instructions for in-service vehicles will be provided at a later time in a Recall bulletin.

REPAIR 1: POSITION BREATHER TUBE - VEHICLES UNDER 500 MILES IN RETAILER INVENTORY

1. Raise vehicle on lift.

2. Locate end of transmission breather tube clipped to the edge of the transmission pan. (Figure 1)

3. Inspect the end of the tube for blockage or damage.

4. Unfasten clip from transmission and remove the clip from the tube. Discard the clip.

5. Guide the end of the breather tube up over the top of the transmission housing.

6. Locate the white three-hole tube-locating clip near the top of the transmission housing.

7. Spray a small amount of silicon lubricant on the breather tubing near the locating clip.

CAUTION:

The orientation of the breather pipes is slightly different on Range Rover and Discovery Series II vehicles

^ On Discovery the Transfer Gearbox breather and the Gearbox breather come from opposite sides of the vehicle.

^ The Discovery breather is secured to an electric harness and must be released from that restraint.

^ Movement of the white clip is limited by the divergence of the tubes.

^ Care must be exercised to avoid crimping or deforming the tubing.

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8. On Range Rover vehicles slide the white tube clip toward the rear of the vehicle until it stops against the bulge at the end of the repositioned

drain tube. (Figure 2)

9. On Discovery Series II vehicles perform the following:

^ Snip the cable tie to release the breather tube from the electrical harness.

^ Slide the white tube clip toward the rear of the vehicle until resistance is met because of the divergence of the transmission and transfer

box tubes. (Figure 3)

^ Verify that the end of the breather tube is parallel with the AT breather and pointed toward the LH rear of the vehicle.

10. Wipe any residual silicon lubricant from tubes.

REPAIR 2: POSITION BREATHER TUBE AND INSPECT AT FLUID FOR CLARITY VEHICLES IN RETAILER INVENTORY OVER 500

MILES

1. Raise the vehicle on a lift.

NOTE:

The testing process outlined below must be followed carefully to avoid unnecessary loss of AT fluid. Done with care and with the proper

tools, approximately 100 cc (3-4 oz.) of fluid can be drained for evaluation. You must have approximately two inches of fluid in the bottom

of your container when the fluid sample is taken.

CAUTION - Fluid drained from the sump pan may be "hot" - Due care and attention must be observed when draining the fluid.

2. Test the fluid to determine the presence of water contamination as follows:

^ Obtain a clean clear plastic container about three inches in diameter and about 6 inches tall.

^ Using a 5 mm Allen wrench break the seal on the transmission drain plug.

^ Orient the Allen wrench with the long portion vertical and carefully unscrew the plug until AT fluid seepage is observed.

^ Hold the container under the plug opening and carefully unscrew the plug until no threads are engaged but maintaining pressure against the

opening.

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^ Tilt the plug slightly to drain the fluid sample required to give 1.5 to 2 inches of fluid in the bottom of the container.

^ Thread the plug back into the opening.

NOTE:

If a level of uncertainty exists as to the correct appearance of the sample, a comparison of the sample taken to new fluid from stock will be

helpful.

3. Visually inspect the fluid for the presence of water contamination against the following parameters:

^ Uncontaminated fluid will have a bright red appearance and will be "clear." You can easily see your finger on the bottom of the clear

container from the top through the 2 inches of drawn fluid.

^ Lightly contaminated fluid will have a deep burgundy red color and cloudy appearance,

^ Heavily contaminated fluid will have a "milky pink" appearance.

WARNING:

Contaminated transmissions may experience intermittent failure of the park lock function. Recall inspection and repair process will be

issued for vehicles that exhibit symptoms of contaminated fluid.

4. If the gearbox fluid exhibits a contaminated appearance THE VEHICLE MUST NOT BE SOLD and no further action can be taken until the

issuance of the formal Recall documentation and procedures.

5. If the gearbox fluid is clear perform the following:

^ Re-route the gearbox breather pipe as described in procedure "Position Breather Tube - Vehicles under 500 miles in Retailer Inventory"

^ Top up the transmission fluid level to the correct level making sure to follow the procedure outlined in TIB 441011981NA5.

^ Install the campaign label as outlined in the next section.

CAMPAIGN LABEL INSTALLATION

NOTE:

Campaign labels may have multiple campaign numbers written on them if multiple campaigns are performed at the same time.

1. When all specified repairs have been accomplished, prepare the campaign label (LRN0002LABEL) as follows:

a) Place the label on a hard surface.

b) Use a ballpoint pen to neatly write/scribe in the bare aluminum areas of the label the following information:

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^ Campaign code performed ("5E25")

^ Your Retailer code

^ The date of repair

2. Peel the label back, apply to radiator support and roll the label with the special roller.

DisclaimerLand Rover Range Rover Technical Service Bulletin # TEC760500 Date: 001027

Body - Front Door Latch Won't Unlock

No: 76/05/00/NAS

Ref:

Issue: 1

Date: 10/27/00

Super-locked Door Latch Removal

AFFECTED VEHICLE RANGE:

Range Rover (LP) All

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SITUATION:

FRONT DOOR LATCH FAILS IN THE SUPER-LOCK MODE

The customer may experience a front door that will not open after it has been locked in the super-lock mode. The latch mechanism can remain

locked even though the remote or the key has been used to unlock it. Other latches in the vehicle will usually unlock correctly.

RESOLUTION:

ACCESS FRONT DOOR LATCH AND DISENGAGE SUPER-LOCK PAWL

From the inside of the vehicle it is possible to access the jammed door latch with the appropriate tools and disengage the super-lock pawl following

the instructions in this TIB.

PARTS INFORMATION:

FQJ103280 Latch Assembly RH Qty 1

FQJ103290 Latch Assembly LH Qty 1

WARRANTY CLAIMS:

76.37.89/39 Time 0.30 hrs.

Release jammed lock mechanism

FAULT CODE: F

Normal warranty policy and procedures apply

REPAIR PROCEDURE

1. Enter the vehicle through the passengers side.

2. Lower the driver's side door window to the fully down position.

3. Tape the edge of the window to protect the area during the following steps.

4. Inspect the door latch with the aid of a flash light and identify the white plastic retainer for the super-lock pawl spring. (Figure 1)

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5. Position a long (18") slender screw driver onto the plastic cover. (Figure 2)

CAUTION:

In the next step exercise care to only apply enough force to break the plastic housing.

^ Too much force could result in damage to surrounding components or the door panel.

^ Windows with applied tints can be damaged by the screwdriver.

6. Tap the screwdriver with a hammer to break the plastic cover.

7. Remove the released spring.

8. Move to the exterior of the door and perform the following:

^ Grasp the outer door handle.

^ Apply body pressure against the outer door surface to reduce load on the latch.

^ Tap the lock assembly motor repeatedly with the screwdriver (Figure 1) until the super-lock pawl releases.

9. Release body pressure and open the door.

10. Follow Workshop Manual Section 76.37.12 procedures to replace the door latch assembly with a new unit.

11. Remove protective tape and verify proper latch operation.

DisclaimerLand Rover Range Rover Technical Service Bulletin # TEC570203 Date: 030523

Steering Column - Squeaking Noise When Turning

No: 57/02/03/NAS

Ref:

Issue: 1

Date: 05/23/03

Steering Column Lubrication

AFFECTED VEHICLE RANGE:

New Range Rover (LM) All

SITUATION:

STEERING COLUMN SQUEAK

A customer may complain of a squeak from the steering column/bulkhead area when turning the steering wheel. The steering column bushing and

grommet fit condition is variable, which can result in misalignment.

RESOLUTION:

39

LUBRICATE STEERING COLUMN GROMMET

A greasing operation has been introduced in manufacturing as an interim solution to the steering column noise. Lubrication of incorrectly aligned

grommets will protect against squeaking. New installations should also be lubricated as described below.

PARTS INFORMATION:

LRN100050S Krytox Spray (Shop supply. Do not claim.)

WARRANTY CLAIMS:

57.40.89/31 Time 0.10 hrs.

Apply Krytox to steering column bushing

FAULT CODE: K

Normal warranty policy and procedures apply.

Material allowance is included in labor operation.

REPAIR PROCEDURE

LUBRICATE BUSHING/GROMMET INTERFACE

1. Open the hood for access and locate the grommet and bushing between the chassis bulkhead and secondary bulkhead.

NOTE:

For illustration purposes only, the column is removed from the vehicle in Figure 1.

2. Ensure grommet and column bushing are correctly fitted and that the column bushing is correctly aligned to the grommet. (Figure 1)

3. Apply Krytox spray (LRN100050S) to the interface of the bushing and grommet.

4. Rotate steering wheel fully in both directions to ensure a uniform distribution of lubricant.

5. Verify that the squeak is no longer present.

DisclaimerLand Rover Range Rover Technical Service Bulletin # TEC100105 Date: 050928

Maintenance - Fluid Specifications/Applications

No: 10/01/05/NAS

Ref: Replaces

10/01/03/NAS

Issue: 1

Date: 28 September 2005

Maintenance Fluid Specifications for

221

"Legacy" Land Rover Vehicles

AFFECTED VEHICLE RANGE:

All "LEGACY Vehicles" (LH, LD, LJ, LP, LT and LM thru 2005)

SITUATION:

SPECIFICATION FOR VEHICLE FLUIDS

Because of the unique nature and limited availability of some Land Rover fluids and lubricants, confusion regarding fluid specifications and

applications can exist. The current listing contains a number of brand names and several Land Rover-specific fluids with part numbers.

NOTE:

Land Rover has announced increased cooperation with Castrol. Castrol product names will be recommended as required fluids and lubricants on

Land Rover vehicles where applicable.

RESOLUTION:

USE CORRECT FLUIDS FOR ALL SYSTEMS

The table of applications and the part number listings are provided to ensure use of the correct fluid specification.

PARTS INFORMATION:

WARRANTY CLAIMS:

Normal warranty policy and procedures apply.

NOTE:

A coolant specification change has been made for Range Rover vehicles. The 2005 specification "G48" fluid is to be used for every FLUID

CHANGE situation. The original Texaco AFC coolant fluid may be used and topped up until a coolant change is required. Mixing Texaco AFC

and BASF G48 for top-up purposes is permitted

CAUTION:

Mixing of the BASF G48 with Texaco XLC coolant used in LR3, Freelander, Discovery Series II and late Range Rover 4.0/4.6 can result in

premature erosion of the cylinder heads or other cooling system deterioration. Unapproved blending of coolants is to be avoided.

Warranty coverage could be affected by the use of unapproved coolants or the incorrect blending of fluids.

Failure to use specified fluids could lead to component failure. If component failures are found to be caused by use of improper fluids, warranty

charge-backs could be impose

222

223

224

225

226

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FLUID APPLICATIONS IN ALL VEHICLES:

DisclaimerLand Rover Range Rover Technical Service Bulletin # TEC760104 Date: 040123

Body - Door Mirror Vibration/Looseness

No: 76/01/04/NAS

Ref: TA037603

Issue: 1

Date: 23 January 2004

Loose Door Mirror Correction

140

AFFECTED VEHICLE RANGE:

New Range Rover (LM) up to 4A144688

SITUATION:

MIRROR VIBRATION OR OBSERVED LOOSE CONDITION

On some vehicles it may be noticed that the exterior mirror glass assembly is loose in its housing. Vibration over uneven surfaces may be evident.

The information in this bulletin supersedes and replaces that published in Technical Alert TA047603.

RESOLUTION:

TIGHTEN MIRROR FASTENERS

Should a customer complain of the vibration or of a loose condition, ensure that the proper torque has been applied to the attachment screws inside

the mirror housing.

PARTS INFORMATION:

Locally sourced

^ Blue Loctite 248

AS400 WARRANTY CLAIMS (CANADA ONLY)

76.10.89/80 Time 0.10 hrs.

Tighten door mirror fasteners - both sides

FAULT CODE: G

DDW WARRANTY CLAIMS:

DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.

Normal warranty policy and procedures apply.

Material allowance is included in labor operation.

REPAIR PROCEDURE

TIGHTEN DOOR MIRROR ATTACHMENT SCREWS

1. Remove the access cover from the underside of the exterior door mirror.

2. Tighten the four fasteners securing the door mirror to the mirror housing to 14 Nm (10.3 lbf.ft.). (Arrowed Figure 1).

141

3. Install the removed access cover.

4. Go to Step 1 and repeat the torque procedure on the unrepaired side.

DisclaimerLand Rover Range Rover Technical Service Bulletin # TECLM204006 Date: 060816

Suspension - Vehicle Lowers Overnight

No.: LM204-006

Issue: 1

Date: August 16, 2006

SECTION: 204-05 - SUSPENSION SYSTEM

Vehicle Lowers Overnight - Air-Spring Leak

AFFECTED VEHICLE RANGE:

Range Rover (LM) VIN: up to 4A160029

CONDITION SUMMARY:

FRONT AIR-SPRING LEAK CAUSES VEHICLE RIDE HEIGHT TO LOWER OVERNIGHT

A customer may report a concern that the vehicle ride height lowers overnight.

Situation:

No obvious system leaks may be found, however, vehicles in a higher mileage range of 30,000-60,000 miles may develop hairline cracks in the

rubber material of the front air-spring. The cracks are likely located at the point where the air-spring rolls over the plastic base.

235

Action:

Should a customer express concern regarding the above, refer to the Repair Procedure detailed in this bulletin to verify the cause and replace the

air-spring as necessary.

PARTS

WARRANTY

REPAIR PROCEDURE

REPLACE FRONT AIR-SPRING

NOTE:

An air leak in the rubber material may be verified using a suitable leak detection fluid.

1. Verify which front air-spring(s) has a leak and requires replacement.

NOTE:

The latest specification air-spring assembly is identified by the manufacturer markings printed on the air-spring air bag as shown in Figure

1.

236

2. Verify the correct specification air-spring assembly has been ordered from the markings as shown in Figure as follows:

^ Right-hand air springs must start with DC01.

^ Left-hand air springs must start with DB01.

NOTE:

GTR lookup sequence is as follows:

GTR Home > NAS > Service Information/LM - Range Rover/2004 > Workshop Manuals > Range Rover - Workshop Manual - Service

Procedures > Bookmark section "60 - Front Suspension" link "60.21.01 Air spring assembly"

3. Refer to Global Technical Reference (GTR) Range Rover (LM) Workshop Manual Section 60 - Front Suspension, operation 60.21.01 Air

spring assembly and replace the front air spring assembly.

DisclaimerLand Rover Range Rover Technical Service Bulletin # TECLRA501001 Date: 060622

Body - Windshield Damage Diagnostic Aid

No.: LRA501-001

Issue: 1

Date: June 22, 2006

SECTION: 501-11

Windshield Damage Diagnostic Aid

AFFECTED VEHICLE RANGE:

All Land Rover Vehicles

CONDITION SUMMARY:

INTERPRETATION OF GLASS DAMAGE SYMPTOMS

Situation:

This information only bulletin has been issued to aid Retailers to determine whether windshield damage has been caused by an outside influence, or

a manufacturing concern.

Action:

Follow the steps outlined in the Repair Procedure to determine whether windshield damage has been the result of outside damage.

PARTS:

230

Information only

WARRANTY:

231

232

233

234

NOTE:

The pages shown offer illustrations of common windshield damage conditions and how to determine if the damage is result of outside influences

(not warrantable) or of manufacturing problems (warrantable)

Normal warranty policy and procedures apply.

DisclaimerLand Rover Range Rover Technical Service Bulletin # TECLTB00061 Date: 070713

Body - Exterior Door Handle Replacement

No.: LTB00061

Issue: 1

Date: 13 July 2007

SECTION: 501-14

Exterior Door Grab Handle - Available as Spare Part

250

AFFECTED VEHICLE RANGE:

Range Rover (LM) VIN: ALL

CONDITION SUMMARY:

GRAB HANDLE AVAILABILITY PERMITS RELEASE HANDLE ASSEMBLY REPAIR

Situation:

Prior to the grab handle kit being available, if a concern existed with the exterior door grab handle the complete release handle mechanism assembly

had to be replaced. Retailers are advised that the exterior door grab handle is now available as a serviceable part.

Action:

If a concern exists with the exterior door grab handle, install the grab handle kit, following the Repair Procedure outlined below. Replacement of the

complete handle mechanism assembly is no longer required for grab handle repairs.

PARTS

WARRANTY:

NOTE:

Repair procedures are under constant review, and therefore times are subject to change; those quoted here must be taken as guidance only.

Always refer to DDW to obtain the latest repair time.

DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.

REPAIR PROCEDURE

GRAB HANDLE REPLACEMENT

NOTE:

Global Technical Reference (GTR) lookup sequence is as follows:

GTR Home> NAS > LM - Range Rover> Service Information/2007 > Workshop Manuals> Bookmark "Body and Paint/501-14 Handles,

Locks Latches and Entry Systems" LINK "Exterior Front Door Handle (76.58.28)"

1. Refer to GTR Section 501-14 and remove the front or rear exterior door handle mechanism as required.

CAUTION:

Upon reassembly the orientation of the return spring must be the same.

2. Observe the orientation of the return spring for later assembly.

WARNING:

Preloaded return spring could cause injury if not properly captured during pivot pin removal.

251

3. Remove the mass balance assembly as follows: (Figure 1)

^ Remove and discard the pivot pin retaining clip.

^ Remove the mass balance pivot pin.

^ Remove the return spring.

4. Remove the exterior door handle pivot pin and remove the grab handle. (Figure 2)

5. Install the exterior door handle pivot pin to the new door grab handle and door handle assembly.

CAUTION:

For proper operation the return spring must be properly oriented.

6. Verify that the return spring is oriented to the correct position as noted in step 2 above.

7. Install the mass balance assembly as follows:

^ Install the return spring.

^ Install the mass balance pivot pin.

252

^ Install the new mass balance pivot spring retaining clip. (Figure 3)

8. Lubricate the mass balance assembly contact area. (Figure 4)

9. Refer to GTR Workshop Manual section: 501-14 and install the repaired exterior door handle mechanism.