Free Ird

INTERMEDIATE REDUCTION DRIVE
Refill
ADJUSTMENTS
Intermediate reduction drive (IRD) fluid - 1. Fill with correct fluid until it just runs from filler/
drain & refill - Non NAS level hole. Allow sufficient time for fluid to flow
and reach a common level in unit.
$% 41.25.06
+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
Drain
2. Fit new sealing washer and tighten filler/level
1. Remove underbelly panel.
+
EXTERIOR FITTINGS, REPAIRS,
plug to 35 Nm (26 lbf.ft).
3. Fit underbelly panel.
Panel - underbelly.
2. Place container beneath IRD unit.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
WARNING: Observe due care when draining
gearbox fluid as the fluid can be very hot.
3. Clean area around filler/level and drain plugs.

4. Remove filler/drain plugs and discard sealing
washers. Allow fluid to drain.
NOTE: The fluid should be drained with the
transmission at normal operating temperature.
5. Fit new sealing washer and tighten drain plug to

35 Nm (26 lbf.ft).
ADJUSTMENTS 41-1
Intermediate reduction drive (IRD)

lubrication system - drain & refill - NAS
$% 41.25.06
Drain
1. Remove underbelly panel
Panel - underbelly.
2. Place container beneath IRD unit.
WARNING: Observe due care when draining
gearbox fluid as the fluid can be very hot.
M41 7687
5. Remove drain plug, discard sealing washer and

allow oil to drain.
NOTE: The fluid should be drained with the
transmission at normal operating temperature.
6. Fit new sealing washer and tighten drain plug to

35 Nm (26 lbf.ft).
Refill
1. Fill with fluid until it just runs from filler/level
hole. Allow sufficient time for fluid to flow and
reach a common level in unit.
+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
2. Fit new sealing washer and tighten filler/level
3. Clean area around filler/level and drain plugs. plug to 35 Nm (26 lbf.ft).
3. Fit underbelly panel
Panel - underbelly.
LRT-41-021
M417853
4. Using LRT-41-021 remove filler plug and

discard sealing washer.
41-2 ADJUSTMENTS
REPAIRS
Intermediate reduction drive (IRD) unit -

Td4
$% 41.25.01.99
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
3. Remove rear beam.

+ FRONT SUSPENSION, REPAIRS,
Rear beam.
4. Remove exhaust front pipe.
+ MANIFOLDS & EXHAUST SYSTEMS
- Td4, REPAIRS, Exhaust pipe - front. 8. Secure LRT-54-026 to drive shaft inboard joint.
5. Drain fluid from IRD. Using a suitable lever, release drive shaft from
+ INTERMEDIATE REDUCTION IRD.
DRIVE, ADJUSTMENTS, Intermediate 9. With assistance, pull hub outwards and release
reduction drive (IRD) fluid - drain & refill - drive shaft from IRD.
Non NAS.
6. Drain gearbox fluid.
+ MANUAL GEARBOX - GETRAG,
ADJUSTMENTS, Gearbox oil - drain and
refill.
+ AUTOMATIC GEARBOX - JATCO,
ADJUSTMENTS, Gearbox fluid - drain &
refill.
10. Remove and discard drive shaft circlip.

11. Reference mark front propeller shaft for
reassembly.
12. Raise one rear wheel for rotation of propeller
shaft to access bolts.
7. Remove 3 bolts securing RH splash shield to
body and remove shield.
REPAIRS 41-3
13. Remove 6 nuts and bolts securing propeller 17. Release clips and disconnect coolant hoses
shaft to IRD drive flange. from IRD.
14. 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.
18. Remove bolt securing engine lower steady to

IRD support bracket.
19. Remove lower engine steady noting that 'TOP'
mark on engine steady faces uppermost.
15. Disconnect breather hose from IRD housing.

16. Position container to collect coolant spillage.
20. Remove 3 bolts securing IRD support bracket

to sump.
41-4 REPAIRS
21. Remove 2 bolts securing support bracket to
IRD.
22. Remove support bracket.
M41 7698
28. Remove and discard 'O' ring from IRD.
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.
REPAIRS 41-5
Refit 14. Clean drive shaft and flange splines.
1. Clean mating faces of IRD and gearbox. 15. Fit new circlip to drive shaft.
2. Lubricate and fit new 'O' ring 16. With assistance, pull hub outwards, align drive
3. With assistance, fit IRD. shaft and fit to IRD taking care not to damage
4. Fit bolts securing IRD to gearbox and tighten oil seal.
sufficiently only to pull mating faces of IRD and 17. Fit splash shield and secure with bolts.
gearbox together at this stage. 18. Fit exhaust front pipe.
5. Fit IRD support brackets, tighten sufficiently to + MANIFOLDS & EXHAUST SYSTEMS
pull mating faces together. - Td4, REPAIRS, Exhaust pipe - front.
6. Final tighten bolts securing IRD to gearbox to 19. Fit rear beam.
90 Nm (66 lbf.ft). + FRONT SUSPENSION, REPAIRS,
7. Final tighten bolts securing IRD support Rear beam.
brackets in the following sequence: 20. Final tighten bolt securing lower engine steady
l M8 bolts securing support brackets to IRD to IRD support bracket to 100 Nm (74 lbf.ft).
37 Nm (22 lbf.ft) 21. Remove stand(s) and lower vehicle.
l M10 bolts securing support brackets to IRD 22. Fill IRD to correct level with fluid.
50 Nm (22 lbf.ft) + INTERMEDIATE REDUCTION
l 3 bolts securing support bracket to cylinder DRIVE, ADJUSTMENTS, Intermediate
block 25 Nm (18 lbf.ft) reduction drive (IRD) fluid - drain & refill -
l 3 bolts securing support bracket to sump at Non NAS.
45 Nm (33 lbf.ft). 23. Fill gearbox with fluid.
8. Position lower engine steady, 'TOP' mark + MANUAL GEARBOX - GETRAG,
uppermost. Fit bolt but do not tighten at this ADJUSTMENTS, Gearbox oil - drain and
stage. refill.
9. Connect coolant hoses and secure with clips. + AUTOMATIC GEARBOX - JATCO,
10. Connect breather hose to IRD housing. ADJUSTMENTS, Gearbox fluid - drain &
11. Clean propeller shaft flange and mating face. refill.
12. Fit propeller shaft to IRD flange and align 24. Connect battery earth lead.
marks. Tighten nuts and bolts to 40 Nm (30 25. Refill cooling system.
lbf.ft). + COOLING SYSTEM - Td4,
13. Inspect drive shaft oil seal, renew if worn or ADJUSTMENTS, Coolant - drain and refill.
damaged.
41-6 REPAIRS

K1.8
$% 41.25.01.99
Remove
Rear beam.
- K SERIES 1.8, REPAIRS, Exhaust pipe -
front.
4. Drain fluid from IRD.
+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
7. Secure LRT-54-026 to drive shaft inboard joint.
Non NAS.
Using a suitable lever, release drive shaft from
5. Drain gearbox oil.
+ MANUAL GEARBOX - PG1,
IRD.
8. With assistance, pull hub outwards and release
drive shaft from IRD.
refill.
CAUTION: Care must be taken not to
damage oil seal when removing drive shaft
from IRD.

REPAIRS 41-7
M12 7142 M12 7144
10. Reference mark front propeller shaft for 19. Remove bolt securing engine lower steady to
reassembly. bracket on sump.
11. Raise one rear wheel for rotation of propeller 20. Remove engine lower steady.
12. Remove 6 nuts and bolts securing propeller
shaft to IRD drive flange.
M12 7165
21. Remove 3 bolts securing lower engine steady

bracket to sump and remove bracket.
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. M12 7166
18. Release clips and disconnect coolant hoses
from IRD.
22. Remove upper bolt securing IRD support
IRD.
41-8 REPAIRS
24. Remove 3 bolts securing IRD support bracket 8. Position engine lower steady bracket to sump,
to sump and remove bracket. 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.
M12 7167
17. Fit new circlip to drive shaft.
18. With assistance, pull hub outwards, align drive
25. Remove 4 bolts securing IRD. shaft and fit to IRD taking care not to damage
26. With assistance, release IRD from gearbox and oil seal.
remove. 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.
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.
M41 7698 + INTERMEDIATE REDUCTION
Non NAS.
24. Refill gearbox with oil.
Refit
1. Clean mating faces of IRD and gearbox.
+ MANUAL GEARBOX - PG1,
2. Lubricate and fit new 'O' ring
refill.
3. With assistance, fit IRD.
25. Connect battery earth lead.
4. Fit bolts securing IRD to gearbox and tighten
26. Refill cooling system.
sufficiently only to pull mating faces of IRD and
gearbox together at this stage.
+ COOLING SYSTEM - K SERIES 1.8,
ADJUSTMENTS, Coolant - refill system.
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).
REPAIRS 41-9

KV6
$% 41.25.01.99
Remove
Rear beam.
- K SERIES KV6, REPAIRS, Front pipe - Non
NAS.
4. NAS models: Remove RH catalytic converter.
+ EMISSION CONTROL, REPAIRS,
Catalytic converter - RH - KV6 - NAS.
5. NAS models:Remove LH exhaust manifold
9. Secure LRT-54-026 to drive shaft inboard joint.
gasket.
Using a suitable lever, release drive shaft from
IRD.
- K SERIES KV6, REPAIRS, Gasket(s) -
10. With assistance, pull hub outwards and release
exhaust manifold - LH - NAS.
drive shaft from IRD.
CAUTION: Care must be taken not to
damage oil seal when removing drive shaft
from IRD.
Non NAS.
reduction drive (IRD) lubrication system -
drain & refill - NAS.
7. Drain gearbox fluid.
+ AUTOMATIC GEARBOX - JATCO,
ADJUSTMENTS, Gearbox fluid - drain &
refill.

41-10 REPAIRS
12. Reference mark front propeller shaft for 19. Disconnect breather hose from IRD housing.
reassembly. 20. Position container to collect coolant spillage.
21. Release clips and disconnect coolant hoses

from IRD.
16. Remove nut securing manifold heat shield to

IRD unit.
17. Remove nut securing heat shield to IRD pinion
housing.
18. Remove 2 bolts securing heat shield and
remove heat shield.
IRD support bracket.
23. Remove lower engine steady noting that 'TOP'
mark on engine steady faces uppermost.
REPAIRS 41-11
24. Remove 3 bolts securing IRD support bracket 28. Remove 4 bolts securing IRD.
to sump. 29. With assistance, release IRD from gearbox and
remove.
M41 7698

to engine front mounting plate.

IRD.
27. Remove support bracket.
41-12 REPAIRS
Refit 21. Fit splash shield and secure with bolts.
1. Clean mating faces of IRD and gearbox. 22. Fit exhaust front pipe.
2. Lubricate and fit new 'O' ring + MANIFOLDS & EXHAUST SYSTEMS
3. With assistance, fit IRD. - K SERIES KV6, REPAIRS, Front pipe - Non
4. Fit bolts securing IRD to gearbox and tighten NAS.
sufficiently only to pull mating faces of IRD and 23. Fit rear beam.
gearbox together at this stage. + FRONT SUSPENSION, REPAIRS,
5. Fit IRD support bracket and tighten bolts Rear beam.
sufficiently only to pull mating faces together. 24. Final tighten bolt securing lower engine steady
6. Final tighten bolts securing IRD to gearbox to to IRD support bracket to 100 Nm (74 lbf.ft).
90 Nm (66 lbf.ft). 25. Fill IRD to correct level with fluid.
7. Final tighten bolts securing IRD support + INTERMEDIATE REDUCTION
bracket in following sequence: DRIVE, ADJUSTMENTS, Intermediate
l 5 bolts securing support bracket to IRD 50 reduction drive (IRD) fluid - drain & refill -
Nm (37 lbf.ft) Non NAS.
l 2 bolts securing support bracket to engine + INTERMEDIATE REDUCTION
front mounting bracket 50 Nm (37 lbf.ft) DRIVE, ADJUSTMENTS, Intermediate
l 3 bolts securing support bracket to sump 88 reduction drive (IRD) lubrication system -
Nm (65 lbf.ft). drain & refill - NAS.
8. Position lower engine steady, 'TOP' mark 26. NAS models: Fit RH catalytic converter.
uppermost. Fit bolt but do not tighten at this + EMISSION CONTROL, REPAIRS,
stage. Catalytic converter - RH - KV6 - NAS.
9. Connect coolant hoses and secure with clips. 27. NAS models: Fit LH exhaust manifold gasket.
10. Connect breather hose to IRD housing. + MANIFOLDS & EXHAUST SYSTEMS
11. Fit manifold heat shield and fit nut securing - K SERIES KV6, REPAIRS, Gasket(s) -
heat shield to pinion housing finger tight. exhaust manifold - LH - NAS.
12. Fit bolts securing manifold heat shield to IRD 28. Fill gearbox with fluid.
support bracket and tighten to 9 Nm (7 lbf.ft). + AUTOMATIC GEARBOX - JATCO,
13. Fit nut securing heat shield to IRD and tighten ADJUSTMENTS, Gearbox fluid - drain &
to 45 Nm (33 lbf.ft). refill.
14. Final tighten nut securing manifold heat shield 29. Connect battery earth lead.
to IRD pinion housing to 25 Nm (18 lbf.ft). 30. Refill cooling system.
15. Clean propeller shaft flange and mating face. + COOLING SYSTEM - K SERIES KV6,
16. Fit propeller shaft to IRD flange and align ADJUSTMENTS, Coolant - drain and refill.
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.
REPAIRS 41-13
Gasket - end cover - IRD housing - Td4 IRD and remove bracket.
$% 41.27.05
Remove
Non NAS.
2. Remove drive shaft RH seal.
DRIVE, REPAIRS, Seal - driveshaft - RH.
9. Remove 3 bolts, securing IRD upper support

10. Remove 2 bolts securing upper support bracket
to IRD and remove bracket.
3. Remove nut securing manifold heat shield to

IRD unit.
4. Remove nut securing heat shield to IRD pinion
housing.
5. Remove 2 bolts securing heat shield and
remove heat shield.
6. Remove lower engine steady.
+ ENGINE - Td4, REPAIRS, Engine
steady - lower. 11. Remove 8 bolts securing end cover to main
case of IRD.
12. Remove end cover.

to sump.
41-14 REPAIRS
Refit
1. Clean remains of old sealant from mating faces Gasket - end cover - IRD housing - KV6
of end cover and IRD main case.
$% 41.27.05
Remove
Non NAS.
2. NAS models: Remove RH catalytic converter.
2. Apply a narrow bead of sealant, Part No. STC + INTERMEDIATE REDUCTION
4600to mating face of end cover. DRIVE, REPAIRS, Seal - driveshaft - RH.
3. Fit end cover to IRD and tighten bolts
progressively to 30 Nm (22 lbf.ft).
5. Final tighten bolts securing IRD support
brackets in the following sequence:
l M10 bolts securing support brackets to IRD
50 Nm (37 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).
6. Fit lower engine steady.
+ ENGINE - Td4, REPAIRS, Engine
steady - lower.
7. Fit heat shield.
8. Fit nut securing heat shield to IRD and tighten 4. Non NAS models:Remove nut securing
to 45 Nm (33 lbf.ft). manifold heat shield to IRD unit.
9. Fit bolts securing manifold heat shield to IRD 5. Non NAS models:Remove nut securing heat
support bracket and tighten to 9 Nm (7 lbf.ft). shield to IRD pinion housing.
10. Fit nut securing heat shield to IRD pinion 6. Non NAS models:Remove 2 bolts securing
housing and tighten to 30 Nm (22 lbf.ft). heat shield and remove heat shield.
11. Fit drive shaft RH seal.
7. Remove engine lower steady.
+ ENGINE - K SERIES KV6, REPAIRS,
DRIVE, REPAIRS, Seal - driveshaft - RH. Engine steady - lower.
Non NAS.
REPAIRS 41-15
8. Remove 3 bolts securing IRD support bracket 11. Remove 8 bolts securing end cover to main
to sump. case of IRD.

to engine front mounting plate.

IRD and remove bracket.
41-16 REPAIRS
Refit 7. Non NAS models: Fit heat shield.
1. Clean remains of old sealant from mating faces 8. Non NAS models: Fit nut securing heat shield
of end cover and IRD main case. to IRD and tighten to 45 Nm (33 lbf.ft).
9. Non NAS models: Fit bolts securing manifold
heat shield to IRD support bracket and tighten
to 9 Nm (7 lbf.ft).
10. Non NAS models: Fit nut securing heat shield
to IRD pinion housing and tighten to 25 Nm (18
lbf.ft).
Non NAS.
2. Apply a narrow bead of sealant, Part No. STC
4600to mating face of end cover.
13. NAS models: Fit RH catalytic converter.
5. Final tighten all bolts 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).
6. Fit engine lower steady.
+ ENGINE - K SERIES KV6, REPAIRS,
Engine steady - lower.
REPAIRS 41-17
Gasket - end cover - IRD housing - K1.8
$% 41.27.05
Remove
Non NAS.
DRIVE, REPAIRS, Seal - driveshaft - RH. M12 7166
7. Remove upper bolt securing IRD support

IRD.
to sump and remove bracket.
M12 7144

beam.
bracket on sump.
5. Remove engine lower steady.
10. Remove 8 bolts securing end cover to main

case of IRD.
bracket on sump.
M12 7165
6. Remove 3 bolts securing lower engine steady

bracket to sump and remove bracket.
41-18 REPAIRS
Refit
1. Clean remains of old sealant from mating faces Seals - primary gear shaft
of end cover and IRD main case.
$% 41.29.02
Remove
1. Remove IRD.
DRIVE, REPAIRS, Intermediate reduction
drive (IRD) unit - K1.8.
drive (IRD) unit - Td4.
drive (IRD) unit - KV6.

4600to mating face of end cover.
5. 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 45 Nm (33 lbf.ft),
l 3 bolts securing support bracket to sump 88 2. Remove 8 bolts securing end cover to main
Nm (65 lbf.ft). case of IRD.
6. Position engine lower steady bracket to sump, 3. Remove end cover.
fit and tighten bolts to 100 Nm (74 lbf.ft).
7. Fit engine lower steady, fit bolts and tighten to
80 Nm (59 lbf.ft).
8.
Non NAS.
4. Remove intermediate shaft and differential

from primary shaft.
REPAIRS 41-19
5. Remove primary shaft from main case.

6. Remove 2 seals from primary shaft.

4600 to mating face of end cover.
7. Remove 2 seals from main case.
Refit
1. Clean primary gear shaft and intermediate
shaft and differential.
2. Clean seal locations.
3. Fit seal to each end of primary gear shaft with
seal lips facing outwards.
4. Fit primary gear shaft to main case.
10. Fit seal protector, part of LRT-41-015 to IRD
5. Fit suitable protection over splines on
splines.
intermediate shaft.
11. Using plain end of LRT-41-015, fit inner seal
6. Carefully fit intermediate shaft to primary shaft.
into main case until it contacts shoulder.
7. Clean remains of old sealant from mating faces
of end cover and IRD main case. CAUTION: The seals are fitted with the main
sealing lips facing away from each other.
41-20 REPAIRS
Seal - pinion gear
$% 41.29.04
Remove
1. Remove pinion housing.
DRIVE, REPAIRS, Seal - pinion gear
housing - Td4.
housing - K1.8.
12. Using flanged end of LRT-41-015 fit outer seal DRIVE, REPAIRS, Seal - pinion gear
housing - KV6 - Non NAS.
to depth dictated by tool flange.
CAUTION: Use end protector of LRT-41-015
to avoid damage to the working surfaces of
housing - KV6 - NAS.
the tool.
CAUTION: Before dismantling the pinion
housing, measure the turning torque on
13. Remove oil seal protector.
existing bearings.
14. Fit IRD.
2. Attach pinion housing to suitable mounting
drive (IRD) unit - K1.8. plate and secure mounting plate in vice.
+ INTERMEDIATE REDUCTION 3. Check pinion torque to turn figure.
drive (IRD) unit - Td4.
drive (IRD) unit - KV6.
4. Reference mark pinion flange and pinion shaft

for assembly purposes.
5. Restrain pinion flange using LRT-51-003.
6. Remove and discard nut.
7. Position pinion housing onto press, fit suitable
adaptor on end of pinion shaft, press pinion
shaft from drive flange and housing.
8. Remove and discard collapsible spacer.
9. Using a suitable lever, remove pinion oil seal.
CAUTION: Take care to avoid damage to oil
seal recess.
10. Remove pinion bearing inner race.
REPAIRS 41-21
Refit 12. If turning torque is too low, carefully tighten nut
1. Clean pinion shaft, drive flange and housing. and recheck reading. If turning torque is too
2. Clean oil seal recess. high, pinion assembly will have to be
3. Lubricate and fit bearing to pinion housing. dismantled and a new collapsible spacer fitted.
4. Lubricate new seal. Reassemble using new nut and recheck turning
5. Using a suitable adapter, press seal into torque.
housing. 13. Check drive flange run-out using a Dial Test
CAUTION: Oil seal must be flush with end of Indicator (DTI).
pinion housing. CAUTION: The drive flange run-out should
not exceed 0.05 mm.
6. Assemble pinion to housing using new
collapsible spacer. 14. Remove pinion housing from vice and
7. Lightly lubricate drive flange splines with mounting plate.
Molybdenum Disulphide grease. 15. Fit pinion housing.
8. Align pinion to drive flange reference marks + INTERMEDIATE REDUCTION
and press flange onto pinion shaft until a 2 mm DRIVE, REPAIRS, Seal - pinion gear
clearance exists in bearings. housing - Td4.
9. Fit pinion assembly to mounting plate and + INTERMEDIATE REDUCTION
secure in vice. DRIVE, REPAIRS, Seal - pinion gear
10. Fit new pinion nut, hold pinion drive flange housing - K1.8.
using LRT-51-003 and tighten pinion nut to 150 + INTERMEDIATE REDUCTION
Nm (111 lbf.ft). DRIVE, REPAIRS, Seal - pinion gear
11. Check pinion torque to turn figure. housing - KV6 - Non NAS.
NOTE: Figure for new bearings is 180 to 200 + INTERMEDIATE REDUCTION
Ncm. DRIVE, REPAIRS, Seal - pinion gear
If original bearing figure is above 20 to 30 Ncm housing - KV6 - NAS.
and below new bearing figure, set to figure
recorded.
If original bearing is below 20 Ncm set to 20 to
30 Ncm.
41-22 REPAIRS
4. Fit LH drive shaft.
Seal - driveshaft - LH - Td4 & KV6 models + DRIVESHAFTS, REPAIRS, Shaft
with both joints - LH.
$% 41.29.08 5. Top-up gearbox fluid level.
+ MAINTENANCE, MAINTENANCE,
Remove Automatic Gearbox – JATCO.
1. Remove LH drive shaft.
+ DRIVESHAFTS, REPAIRS, Shaft
2. Carefully remove and discard oil seal, take care
not to damage oil seal recess.
Refit
1. Clean oil seal recess.
CAUTION: Oil seal is waxed on outer
diameter and must not be lubricated before
fitting.
2. Models with manual gearbox:Using LRT-54-

025 and LRT-99-003, fit new oil seal.
3. Models with automatic gearbox: Using LRT-

44-027, fit new oil seal.
REPAIRS 41-23
Seal - drive shaft - LH - K1.8
$% 41.29.08
Remove
1. Remove LH drive shaft.
2. Carefully remove oil seal from differential
housing, discard oil seal.
Refit
1. Thoroughly clean oil seal recess in differential
housing, splines and oil seal running surface on
drive shaft.
5. Fully insert oil seal protector tool, Unipart TRV
100060, into differential oil seal so that oil seal
lip is protected and that the split end of tool is
butted correctly.
6. Fit LH drive shaft.
2. Fit handle LRT-37-027 into seal replacer

adaptor, LRT-37-032.
3. Position new oil seal onto LRT-37-032 with
sealing lip facing towards differential housing.
4. Carefully drift oil seal into housing until fully
seated in recess.
41-24 REPAIRS
Seal - driveshaft - RH Seal - pinion gear housing - Td4
$% 41.29.09 $% 41.29.11
Remove Remove
1. Remove RH drive shaft. 1. Raise front of vehicle.
+ DRIVESHAFTS, REPAIRS, Shaft WARNING: Do not work on or under a
with both joints - RH. vehicle supported only by a jack. Always
2. Carefully remove and discard oil seal, take care support the vehicle on safety stands.
not to damage oil seal recess.
Refit
1. Clean oil seal recess.
Panel - underbelly.
Non NAS.
2. Locate seal on tool LRT-37-031 and replacer

LRT-37-027 with sealing lip facing towards
housing.
3. Carefully drift oil seal into housing until fully
seated in recess.
4. Fit RH drive shaft.
with both joints - RH.
5. Reference mark front propeller shaft for
reassembly.
REPAIRS 41-25
Refit
1. Clean pinion housing and mating face on IRD
casing.
2. Clean spacing washer.
3. Fit spacing washer to IRD.
4. Lubricate new 'O' ring with IRD fluid and fit to
groove in pinion housing.
5. Fit pinion housing.
6. Fit nuts securing pinion housing and tighten to
25 Nm (18 lbf.ft).
7. Ensure mating face of propeller shaft and IRD
drive flange are clean.
8. Fit propeller shaft to IRD flange and align
lbf.ft).
8. Remove 5 nuts securing pinion housing.
9. Remove pinion housing.
Non NAS.
10. Lower axle and remove jack.
Panel - underbelly.
12. Remove stands and lower vehicle.
10. Remove and discard 'O' ring.

11. Remove and retain spacing washer.
41-26 REPAIRS
7. Remove 3 nuts securing mass damper to
Seal - pinion gear housing - K1.8 pinion housing.
8. Remove mass damper.
$% 41.29.11 9. Remove 2 remaining nuts securing pinion
housing.
Remove 10. Remove pinion housing.
Panel - underbelly.
Non NAS.
11. Remove and discard 'O' ring.

12. Remove and retain spacing washer.
Refit
1. Clean pinion housing and mating face on IRD
casing.
2. Clean spacing washer.
M12 7142 3. Fit spacing washer to IRD.
4. Lubricate new 'O' ring with IRD fluid and fit to
4. Reference mark front propeller shaft for groove in pinion housing.
reassembly. 5. Fit pinion housing.
5. Remove 6 nuts and bolts securing propeller 6. Fit mass damper and fit nuts finger tight.
shaft to IRD drive flange. 7. Fit remaining nuts securing pinion housing and
6. Release propeller shaft from IRD drive flange tighten all nuts to 25 Nm (18 lbf.ft).
and tie shaft aside. 8. Ensure mating face of propeller shaft and IRD
CAUTION: Care must be taken to support drive flange are clean.
the Tripode joint when removed from the 9. Fit propeller shaft to IRD flange and align
IRD unit. To avoid damage to gaiter or steel marks. Tighten nuts and bolts to 40 Nm (30
can, the joint should not be allowed to fully lbf.ft).
Non NAS.
11. Lower axle and remove jack.
Panel - underbelly.
REPAIRS 41-27

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INTERMEDIATE REDUCTION DRIVE

3. Clean area around filler/level and drain plugs.

5. Fit new sealing washer and tighten drain plug to

Intermediate reduction drive (IRD)

5. Remove drain plug, discard sealing washer and

6. Fit new sealing washer and tighten drain plug to

4. Using LRT-41-021 remove filler plug and

Intermediate reduction drive (IRD) unit -

3. Remove rear beam.

10. Remove and discard drive shaft circlip.

18. Remove bolt securing engine lower steady to

15. Disconnect breather hose from IRD housing.

20. Remove 3 bolts securing IRD support bracket

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

23. Remove 3 bolts, securing IRD upper support

26. Remove 4 bolts securing IRD.

Intermediate reduction drive (IRD) unit -

6. Remove 3 bolts securing RH splash shield to

9. Remove and discard drive shaft circlip.

M12 7142 M12 7144

21. Remove 3 bolts securing lower engine steady

14. Remove 3 nuts securing mass damper to

19. Fit splash shield and secure with bolts.

Intermediate reduction drive (IRD) unit -

11. Remove and discard drive shaft circlip.

8. Remove 3 bolts securing RH splash shield to

21. Release clips and disconnect coolant hoses

16. Remove nut securing manifold heat shield to

25. Remove 2 bolts securing IRD support bracket

26. Remove 5 bolts securing support bracket to

9. Remove 3 bolts, securing IRD upper support

3. Remove nut securing manifold heat shield to

7. Remove 3 bolts securing IRD support bracket

9. Remove 2 bolts securing IRD support bracket

10. Remove 5 bolts securing support bracket to

Gasket - end cover - IRD housing - K1.8

7. Remove upper bolt securing IRD support

3. Remove bolt securing engine lower steady to

10. Remove 8 bolts securing end cover to main

6. Remove 3 bolts securing lower engine steady

2. Apply a narrow bead of sealant, Part No. STC

4. Remove intermediate shaft and differential

5. Remove primary shaft from main case.

8. Apply a narrow bead of sealant, Part No. STC

7. Remove 2 seals from main case.

Seal - pinion gear

4. Reference mark pinion flange and pinion shaft

10. Remove pinion bearing inner race.

2. Models with manual gearbox:Using LRT-54-

3. Models with automatic gearbox: Using LRT-

Seal - drive shaft - LH - K1.8

2. Fit handle LRT-37-027 into seal replacer

Seal - driveshaft - RH Seal - pinion gear housing - Td4

2. Locate seal on tool LRT-37-031 and replacer

10. Remove and discard 'O' ring.

11. Remove and discard 'O' ring.

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