Freelander Service Procedures
INTERMEDIATE REDUCTION DRIVE
REPAIRS
41-13
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 support bracket to IRD 50
Nm (37 lbf.ft)
l
2 bolts securing support bracket to engine
front mounting bracket 50 Nm (37 lbf.ft)
l
3 bolts securing support bracket to sump 88
Nm (65 lbf.ft).
8. Position lower engine steady, 'TOP' mark
uppermost. Fit bolt but do not tighten at this
stage.
9. Connect coolant hoses and secure with clips.
10. Connect breather hose to IRD housing.
11. Fit manifold heat shield and fit nut securing
heat shield to pinion housing finger tight.
12. Fit bolts securing manifold heat shield to IRD
support bracket and tighten to 9 Nm (7 lbf.ft).
13. Fit nut securing heat shield to IRD and tighten
to 45 Nm (33 lbf.ft).
14. Final tighten nut securing manifold heat shield
to IRD pinion housing to 25 Nm (18 lbf.ft).
15. Clean propeller shaft flange and mating face.
16. Fit propeller shaft to IRD flange and align
marks. Tighten nuts and bolts to 40 Nm (30
lbf.ft).
17. Inspect drive shaft oil seal, renew if worn or
damaged.
18. Clean drive shaft and flange splines.
19. Fit new circlip to drive shaft.
20. 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.
21. Fit splash shield and secure with bolts.
22. Fit exhaust front pipe.
- K SERIES KV6, REPAIRS, Front pipe - Non
NAS.
23. Fit rear beam.
24. Final tighten bolt securing lower engine steady
to IRD support bracket to 100 Nm (74 lbf.ft).
25. Fill IRD to correct level with fluid.
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
Non NAS.
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) lubrication system -
drain & refill - NAS.
26. NAS models: Fit RH catalytic converter.
Catalytic converter - RH - KV6 - NAS.
27. NAS models: Fit LH exhaust manifold gasket.
- K SERIES KV6, REPAIRS, Gasket(s) -
exhaust manifold - LH - NAS.
28. Fill gearbox with fluid.
ADJUSTMENTS, Gearbox fluid - drain &
refill.
29. Connect battery earth lead.
30. Refill cooling system.