Freelander 1. Manual - part 153

INTERMEDIATE REDUCTION DRIVE

REPAIRS

41-5

20. Remove 3 bolts securing IRD support bracket 

to sump.

21. Remove 2 bolts securing support bracket to 

IRD.

22. Remove support bracket.

23. Remove 3 bolts, securing IRD upper support 

bracket to cylinder block.

24. Remove 2 bolts securing upper support bracket 

to IRD.

25. Remove IRD upper support bracket.

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

remove.

28. 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 brackets, tighten sufficiently 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 

brackets in the following sequence:

l

M8 bolts securing support brackets to IRD 
37 Nm (22 lbf.ft)

l

M10 bolts securing support brackets to IRD 
50 Nm (22 lbf.ft)

l

3 bolts securing support bracket to cylinder 
block 25 Nm (18 lbf.ft)

l

3 bolts securing support bracket to sump at 
45 Nm (33 lbf.ft).

M41 7698

INTERMEDIATE REDUCTION DRIVE

41-6

REPAIRS

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

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

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

damaged.

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

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

17. Fit splash shield and secure with bolts.
18. Fit exhaust front pipe.

 

 + 

 MANIFOLDS & EXHAUST SYSTEMS 

- Td4, REPAIRS, Exhaust pipe - front.

19. Fit rear beam.

 

 + 

 FRONT SUSPENSION, REPAIRS, 

Rear beam.

20. Final tighten bolt securing lower engine steady 

to IRD support bracket to 100 Nm (74 lbf.ft).

21. Remove stand(s) and lower vehicle.
22. Fill IRD to correct level with fluid.

 

 + 

 INTERMEDIATE REDUCTION 

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

23. Fill gearbox with fluid.

 

 + 

 MANUAL GEARBOX - GETRAG, 

ADJUSTMENTS, Gearbox oil - drain and 
refill.
 

 + 

 AUTOMATIC GEARBOX - JATCO, 

ADJUSTMENTS, Gearbox fluid - drain & 
refill.

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

 

 + 

 COOLING SYSTEM - Td4, 

ADJUSTMENTS, Coolant - drain and refill.

Intermediate reduction drive (IRD) unit - 
K1.8

$% 41.25.01.99

Remove

1. Disconnect battery earth lead.
2. Remove rear beam.

 

 + 

 FRONT SUSPENSION, REPAIRS, 

Rear beam.

3. Remove exhaust front pipe.

 

 + 

 MANIFOLDS & EXHAUST SYSTEMS 

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

4. Drain fluid from IRD.

 

 + 

 INTERMEDIATE REDUCTION 

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

5. Drain gearbox oil.

 

 + 

 MANUAL GEARBOX - PG1, 

ADJUSTMENTS, Gearbox oil - drain and 
refill.

6. Remove 3 bolts securing RH splash shield to 

body and remove shield.

INTERMEDIATE REDUCTION DRIVE

REPAIRS

41-7

7. Secure LRT-54-026 to drive shaft inboard joint. 

Using a suitable lever, release drive shaft from 
IRD.

8. With assistance, pull hub outwards and release 

drive shaft from IRD.

CAUTION: Care must be taken not to 
damage oil seal when removing drive shaft 
from IRD.

9. Remove and discard drive shaft circlip.

10. Reference mark front propeller shaft for 

reassembly.

11. Raise one rear wheel for rotation of propeller 

shaft to access bolts.

12. Remove 6 nuts and bolts securing propeller 

shaft to IRD drive flange.

13. Release propeller shaft from IRD drive flange 

and tie shaft aside.

CAUTION: Care must be taken to support 
the Tripode joint when removed from the 
IRD unit. To avoid damage to gaiter or steel 
can, the joint should not be allowed to fully 
extend or be dropped.

14. Remove 3 nuts securing mass damper to 

pinion housing.

15. Remove mass damper.
16. Disconnect breather hose from IRD housing.
17. Position container to collect coolant spillage.
18. Release clips and disconnect coolant hoses 

from IRD.

M12 7142

INTERMEDIATE REDUCTION DRIVE

41-8

REPAIRS

19. Remove bolt securing engine lower steady to 

bracket on sump.

20. Remove engine lower steady.

21. Remove 3 bolts securing lower engine steady 

bracket to sump and remove bracket.

22. Remove upper bolt securing IRD support 

bracket to cylinder block.

23. Remove 5 bolts securing support bracket to 

IRD.

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.

M12 7144

M12 7165

M12 7166

M12 7167

M41 7698