Intermediate reduction drive (IRD) unit - K1.8 (page 3 of 3)

INTERMEDIATE REDUCTION DRIVE

REPAIRS

41-9

24. Remove 3 bolts securing IRD support bracket 

to sump and remove bracket.

25. Remove 4 bolts securing IRD.
26. With assistance, release IRD from gearbox and 

remove.

27. Remove and discard 'O' ring from IRD.

Refit

1. Clean mating faces of IRD and gearbox.
2. Lubricate and fit new 'O' ring
3. With assistance, fit IRD.
4. Fit bolts securing IRD to gearbox and tighten 

sufficiently only to pull mating faces of IRD and 
gearbox together at this stage.

5. Fit IRD support bracket and tighten bolts 

sufficiently only to pull mating faces together.

6. Final tighten bolts securing IRD to gearbox to 

90 Nm (66 lbf.ft).

7. Final tighten bolts securing IRD support bracket 

in following sequence:   

l

5 bolts securing IRD support bracket to IRD 
50 Nm (37 lbf.ft)

l

1 bolt securing support bracket to cylinder 
block to 45 Nm (33 lbf.ft)

l

3 bolts securing support bracket to sump 88 
Nm (65 lbf.ft).

8. Position engine lower steady bracket to sump, 

fit and tighten bolts to 100 Nm (74 lbf.ft).

9. Fit engine lower steady, fit bolt securing steady 

to gearbox bracket but do not tighten at this 
stage.

10. Connect coolant hoses and secure with clips.
11. Connect breather hose to IRD housing.
12. Fit mass damper to pinion housing, fit nuts and 

tighten to 25 Nm (18 lbf.ft).

13. Clean propeller shaft flange and mating face.
14. Fit propeller shaft to IRD flange and align 

marks. Tighten nuts and bolts to 40 Nm (30 
lbf.ft).

15. Inspect drive shaft oil seal, renew if worn or 

damaged.

16. Clean drive shaft and flange splines.
17. Fit new circlip to drive shaft.
18. With assistance, pull hub outwards, align drive 

shaft and fit to IRD taking care not to damage 
oil seal.

CAUTION: Pull the drive shaft to ensure the 
circlip is fully engaged and retains the shaft.

19. Fit splash shield and secure with bolts.
20. Fit exhaust front pipe.

 

 + 

 MANIFOLDS & EXHAUST SYSTEMS 

- K SERIES 1.8, REPAIRS, Exhaust pipe - 
front.

21. Fit rear beam.

 

 + 

 FRONT SUSPENSION, REPAIRS, 

Rear beam.

22. Final tighten bolt securing lower engine steady 

to sump bracket to 80 Nm (59 lbf.ft).

23. Fill IRD to correct level with fluid.

 

 + 

 INTERMEDIATE REDUCTION 

DRIVE, ADJUSTMENTS, Intermediate 
reduction drive (IRD) fluid - drain & refill - 
Non NAS.

24. Refill gearbox with oil.

 

 + 

 MANUAL GEARBOX - PG1, 

ADJUSTMENTS, Gearbox oil - drain and 
refill.

25. Connect battery earth lead.
26. Refill cooling system.

 

 + 

 COOLING SYSTEM - K SERIES 1.8, 

ADJUSTMENTS, Coolant - refill system.

M12 7167

M41 7698