Page 416 of 1007
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:
l5 bolts securing support bracket to IRD 50
Nm (37 lbf.ft)
l2 bolts securing support bracket to engine
front mounting bracket 50 Nm (37 lbf.ft)
l3 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.
+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Front pipe - Non
NAS.
23.Fit rear beam.
+ FRONT SUSPENSION, REPAIRS,
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.
+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
Non NAS.
+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) lubrication system -
drain & refill - NAS.
26. NAS models: Fit RH catalytic converter.
+ EMISSION CONTROL, REPAIRS,
Catalytic converter - RH - KV6 - NAS.
27. NAS models: Fit LH exhaust manifold gasket.
+ MANIFOLDS & EXHAUST SYSTEMS
- K SERIES KV6, REPAIRS, Gasket(s) -
exhaust manifold - LH - NAS.
28.Fill gearbox with fluid.
+ AUTOMATIC GEARBOX - JATCO,
ADJUSTMENTS, Gearbox fluid - drain &
refill.
29.Connect battery earth lead.
30.Refill cooling system.
+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
Page 417 of 1007
INTERMEDIATE REDUCTION DRIVE
41-14 REPAIRS
Gasket - end cover - IRD housing - Td4
$% 41.27.05
Remove
1.Drain fluid from IRD.
+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
Non NAS.
2.Remove drive shaft RH seal.
+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Seal - driveshaft - RH.
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.
7.Remove 3 bolts securing IRD support bracket
to sump.8.Remove 2 bolts securing support bracket to
IRD and remove bracket.
9.Remove 3 bolts, securing IRD upper support
bracket to cylinder block.
10.Remove 2 bolts securing upper support bracket
to IRD and remove bracket.
11.Remove 8 bolts securing end cover to main
case of IRD.
12.Remove end cover.
Page 418 of 1007
INTERMEDIATE REDUCTION DRIVE
REPAIRS 41-15
Refit
1.Clean remains of old sealant from mating faces
of end cover and IRD main case.
2.Apply a narrow bead of sealant, Part No. STC
4600to mating face of end cover.
3.Fit end cover to IRD and tighten bolts
progressively to 30 Nm (22 lbf.ft).
4.Fit IRD support bracket and tighten bolts
sufficiently only to pull mating faces together.
5.Final tighten bolts securing IRD support
brackets in the following sequence:
lM10 bolts securing support brackets to IRD
50 Nm (37 lbf.ft)
l3 bolts securing support bracket to cylinder
block 25 Nm (18 lbf.ft)
l3 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
to 45 Nm (33 lbf.ft).
9.Fit bolts securing manifold heat shield to IRD
support bracket and tighten to 9 Nm (7 lbf.ft).
10.Fit nut securing heat shield to IRD pinion
housing and tighten to 30 Nm (22 lbf.ft).
11.Fit drive shaft RH seal.
+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Seal - driveshaft - RH.
12.Fill IRD to correct level with fluid.
+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
Non NAS.
Gasket - end cover - IRD housing - KV6
$% 41.27.05
Remove
1.Drain fluid from IRD.
+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
Non NAS.
+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) lubrication system -
drain & refill - NAS.
2. NAS models: Remove RH catalytic converter.
+ EMISSION CONTROL, REPAIRS,
Catalytic converter - RH - KV6 - NAS.
3.Remove drive shaft RH seal.
+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Seal - driveshaft - RH.
4. Non NAS models:Remove nut securing
manifold heat shield to IRD unit.
5. Non NAS models:Remove nut securing heat
shield to IRD pinion housing.
6. Non NAS models:Remove 2 bolts securing
heat shield and remove heat shield.
7.Remove engine lower steady.
+ ENGINE - K SERIES KV6, REPAIRS,
Engine steady - lower.
Page 419 of 1007
INTERMEDIATE REDUCTION DRIVE
41-16 REPAIRS
8.Remove 3 bolts securing IRD support bracket
to sump.
9.Remove 2 bolts securing IRD support bracket
to engine front mounting plate.
10.Remove 5 bolts securing support bracket to
IRD and remove bracket.11.Remove 8 bolts securing end cover to main
case of IRD.
12.Remove end cover.
Page 420 of 1007
INTERMEDIATE REDUCTION DRIVE
REPAIRS 41-17
Refit
1.Clean remains of old sealant from mating faces
of end cover and IRD main case.
2.Apply a narrow bead of sealant, Part No. STC
4600to mating face of end cover.
3.Fit end cover to IRD and tighten bolts
progressively to 30 Nm (22 lbf.ft).
4.Fit IRD support bracket and tighten bolts
sufficiently only to pull mating faces together.
5.Final tighten all bolts in following sequence:
l5 bolts securing support bracket to IRD 50
Nm (37 lbf.ft)
l2 bolts securing support bracket to engine
front mounting bracket 50 Nm (37 lbf.ft)
l3 bolts securing support bracket to sump 88
Nm (65 lbf.ft).
6.Fit engine lower steady.
+ ENGINE - K SERIES KV6, REPAIRS,
Engine steady - lower.7. Non NAS models: Fit heat shield.
8. Non NAS models: Fit nut securing heat shield
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).
11.Fit drive shaft RH seal.
+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Seal - driveshaft - RH.
12.Fill IRD to correct level with fluid.
+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
Non NAS.
+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) lubrication system -
drain & refill - NAS.
13. NAS models: Fit RH catalytic converter.
+ EMISSION CONTROL, REPAIRS,
Catalytic converter - RH - KV6 - NAS.
Page 421 of 1007
INTERMEDIATE REDUCTION DRIVE
41-18 REPAIRS
Gasket - end cover - IRD housing - K1.8
$% 41.27.05
Remove
1.Drain fluid from IRD.
+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
Non NAS.
2.Remove drive shaft RH seal.
+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Seal - driveshaft - RH.
3.Remove bolt securing engine lower steady to
beam.
4.Remove bolt securing engine lower steady to
bracket on sump.
5.Remove engine lower steady.
6.Remove 3 bolts securing lower engine steady
bracket to sump and remove bracket.7.Remove upper bolt securing IRD support
bracket to cylinder block.
8.Remove 5 bolts securing support bracket to
IRD.
9.Remove 3 bolts securing IRD support bracket
to sump and remove bracket.
10.Remove 8 bolts securing end cover to main
case of IRD.
11.Remove end cover.
12.Remove bolt securing engine lower steady to
bracket on sump.
M12 7144
M12 7165
M12 7166
Page 422 of 1007
INTERMEDIATE REDUCTION DRIVE
REPAIRS 41-19
Refit
1.Clean remains of old sealant from mating faces
of end cover and IRD main case.
2.Apply a narrow bead of sealant, Part No. STC
4600to mating face of end cover.
3.Fit end cover to IRD and tighten bolts
progressively to 30 Nm (22 lbf.ft).
4.Fit IRD support bracket and tighten bolts
sufficiently only to pull mating faces together.
5.Final tighten bolts securing IRD support bracket
in following sequence:
l5 bolts securing IRD support bracket to IRD
50 Nm (37 lbf.ft),
l1 bolt securing support bracket to cylinder
block 45 Nm (33 lbf.ft),
l3 bolts securing support bracket to sump 88
Nm (65 lbf.ft).
6.Position engine lower steady bracket to sump,
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.
9.Fit drive shaft RH seal.
+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Seal - driveshaft - RH.
10.Fill IRD to correct level with fluid.
+ INTERMEDIATE REDUCTION
DRIVE, ADJUSTMENTS, Intermediate
reduction drive (IRD) fluid - drain & refill -
Non NAS.
Seals - primary gear shaft
$% 41.29.02
Remove
1.Remove IRD.
+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Intermediate reduction
drive (IRD) unit - K1.8.
+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Intermediate reduction
drive (IRD) unit - Td4.
+ INTERMEDIATE REDUCTION
DRIVE, REPAIRS, Intermediate reduction
drive (IRD) unit - KV6.
2.Remove 8 bolts securing end cover to main
case of IRD.
3.Remove end cover.
4.Remove intermediate shaft and differential
from primary shaft.
Page 436 of 1007
AUTOMATIC GEARBOX - JATCO
ADJUSTMENTS 44-1
AUTOMATIC GE ARBOX - JATCO ADJUST ME NTS
Inhibitor switch - adjust
$% 44.15.18
Adjust
1.Set gear selector lever to 'N' position.
2.Loosen 2 bolts securing inhibitor switch to
gearbox casing.
3.Fit tool LRT-44-018 to selector lever on
gearbox, rotate inhibitor switch sufficient to
insert tool alignment pin through tool lever into
inhibitor switch.
4.Tighten inhibitor switch bolts to 3 Nm (2.2
lbf.ft)and remove LRT-44-018.
5.Check that the engine will start in 'P' and 'N'
positions and is inhibited when drive positions
are selected.
M44 1645A
LRT-44-018
