Freelander Service Procedures
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.
- K SERIES 1.8, REPAIRS, Exhaust pipe -
front.
21. Fit 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.
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
Non NAS.
24. Refill gearbox with oil.
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
