Issue with new IRD

filterthis · 13th July 2012, 02:44 PM

Hi Everyone,

First time posting so the following relates to my 1999 diesel (L-series) freelander (manual).

About 18 months ago I completely lunched the IRD (as per usual!) and replaced it with a new one. At the same time I removed the rear prop shaft and left it running in 2WD. I still have not quite gotten around to getting a new VC and reinstalling that bit!

I just replaced the oil in the IRD and was very disturbed to find a fair amount of ultra fine metal powder in it. This was mostly on the drain plug magnet but there was enough of it to be quite startling.

Could I have done something wrong during the installation that might be damaging the IRD?

The car has a number of other symptoms including serious shudder on takeoff (has always done this), drive train shudder (almost a rattle) when releasing the clutch on low speed down changes (<60km/h). Most recently there is a sound like something is rubbing when accelerating. This noise disappears as soon as I back off. The drive train is completely silent when coasting out of gear.

Oh yeah, there is also a fairly noisy whine when changing back down through the gears. I assumed this was because the gearbox was on its way out due to the IRD/VC issue but I was not going to do anything about it until it failed. The oil comes out of the gear box as clean as a whistle.

I have pushed, prodded, shaken and levered most of the external parts of the drive train and can't find anything obviously wrong.

If anyone has any suggestions I would greatly appreciate any advice (except selling the vehicle as I am an enthusiast and cannot be reasoned with!).

Many thanks,
PL

**101RRS** · 13th July 2012, 03:11 PM

If the IRD was new and this is its first oil change I would not worry about the fluff on the pickup as long as it is fluff and no chunky bits - this is just from the bedding in process but with a new IRD I would have replaced the oil a couple of thousand kms after installation to get rid of this wear material.

My guess would be that your other issues are gearbox/clutch related an unlikely to be IRD. When a VCU fails, while it is possible to damage the gearbox it is unlikely as the weak spot are the rear PTO bearings in the IRD and the associated rear PTO crown and pinion un meshing. The front drive differential and drive in the IRD are usually no impacted - of course if the damage is catastrophic with shrapnel every where the whole IRD is taken out.

As I said my guess (and it is a guess) would be the clutch/gearbox.

Garry

filterthis · 16th July 2012, 01:44 PM

Thanks for that advice. It is reassuring to hear that the IRD is probably OK. I was really scratching my head over what I could possibly have done to stuff up the installation. I guess its time to pull the clutch and have a look. That should be fun.

Cheers, PL

rokdog74 · 15th January 2013, 10:39 AM

Hi, Just wondering how you went with the clutch/gearbox issue, im looking at replacing my clutch with a borg and wondered what kind of job it it.

Cheers

**ghostpsalm** · 20th January 2013, 09:33 PM

I just finished changing the clutch slave cylinder (inside gearbox) in my 2001 TD4. It has the Getrag gearbox in it; I am unsure about the earlier models if they have the same box, I imagine not.

There was nothing too complicated about the job, except that you practically need to pull everything off to get to it (lower beam, IRD, etc, etc.). You may want to ensure you have friends or a few jacks to make the job easier.

Any questions, I'll do my best to answer.

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