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Intermediate Reduction Drive Unit: Installation

  1. Clean mating faces of IRD and transmission. Lubricate and fit NEW "O" ring. With assistance, install IRD. Install bolts securing IRD to transmission and tighten sufficiently only to pull mating faces of IRD and transmission together at this stage.
  2. Install IRD support bracket and tighten bolts sufficiently only to pull mating faces together. Final tighten bolts securing IRD to transmission to specification. See TORQUE SPECIFICATIONS  .
  3. Final tighten IRD support bracket bolts to specification in the following sequence:
    1. Bolts (5) securing support bracket-to-IRD. See Figure .
    2. Bolts (2) securing support bracket-to-engine front mounting bracket. See Figure .
    3. Bolts (3) securing support bracket-to-sump. See Figure .
    See TORQUE SPECIFICATIONS  .
  4. Position lower engine steady, TOP mark facing upward. Install bolt but DO NOT tighten at this stage. Connect coolant hoses and secure with clips. Connect breather hose to IRD housing.
  5. Install manifold heat shield and install nut securing heat shield to pinion housing finger tight. Install bolts securing manifold heat shield to IRD support bracket and tighten to specification. See TORQUE SPECIFICATIONS  .
  6. Install nut securing heat shield to IRD and tighten to specification. See TORQUE SPECIFICATIONS  . Final tighten nut securing manifold heat shield to IRD pinion housing to specification.
  7. Clean drive shaft flange and mating face. Install drive shaft to IRD flange, align marks and tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS  . Inspect axle shaft oil seal, renew if worn or damaged.
    8. CAUTION: After installing axle shaft, pull on axle shaft to ensure circlip is fully engaged and retains axle shaft.
  8. Clean axle shaft and flange splines. Install NEW circlip to axle shaft. With assistance, pull hub outwards, align axle shaft and install to IRD taking care not to damage oil seal. Install splash shield and secure with bolts.
    9. CAUTION: Nuts and bolts must be tightened with weight of vehicle on suspension.
  9. Position and align rear beam. Install NEW bolts securing rear beam to body, but do not fully tighten at this stage. Locate lower arm bushings, install but do not fully tighten bolts.
  10. Clean bushing housing and mating faces on rear beam. Align bushing housings ensuring roll pin is correctly located. Install bolts and tighten to specification. See TORQUE SPECIFICATIONS  .
  11. Tighten rear beam-to-body bolts to specification. See TORQUE SPECIFICATIONS  . Install anti-roll bar saddle clamp bolts and tighten to specification. Align engine lower steady, install bolt and tighten to specification.
  12. Lower vehicle. Tighten lower arm front bushing bolts to specification. See TORQUE SPECIFICATIONS  . Tighten lower arm rear bushing nuts to specification.
  13. Final tighten bolt securing lower engine steady-to-IRD support bracket to specification. See TORQUE SPECIFICATIONS  . Fill IRD to correct level with fluid. See INTERMEDIATE REDUCTION DRIVE (IRD)  under OIL DRAIN & REFILL PROCEDURE.
  14. Clean right catalytic converter and mating face. Using a NEW gasket, install catalytic converter and nuts, but do not tighten at this stage. Install exhaust pipe clamp and bolts, but do not tighten at this stage. Connect post catalytic converter H02S connector and install to bracket. Install HO2S harness into clips.
  15. Install heat shields and tighten bolts to specification. See TORQUE SPECIFICATIONS  .
  16. Clean intermediate pipe and mating faces. Install NEW gasket to front pipe flange. Install intermediate pipe and connect mounting. Tighten intermediate pipe flange nuts to specification. See TORQUE SPECIFICATIONS  .
  17. Install tail pipe and silencer. Clean mating faces of tail pipe and intermediate pipe. Install tail pipe and connect rubber mountings. Tighten tail pipe clamp nut to specification. See TORQUE SPECIFICATIONS  .
  18. Tighten catalytic converter-to-manifold nuts to specification. See TORQUE SPECIFICATIONS  . Tighten bolts securing clamp to specification. Connect pre-catalytic converter H02S connector and install to bracket. Install harness into clips. Install acoustic cover.
  19. Clean left exhaust manifold and mating faces. Using NEW gaskets, install exhaust manifold and tighten nuts to cylinder head to specification. See TORQUE SPECIFICATIONS  . Connect H02S connectors, secure connectors to brackets and harness to clips.
  20. Clean A/C compressor and mounting bracket mating faces. Install compressor heat shield. Position compressor to mounting and align heat shield. Install and tighten bolts to specification. See TORQUE SPECIFICATIONS  .
  21. Using a 3/8" drive breaker bar, raise ancillary drive belt tensioner and install drive belt to pulleys. Install underbelly panel. See UNDERBELLY PANEL  under REMOVAL & INSTALLATION.
  22. Install engine acoustic cover. Connect air intake and air bypass hoses, secure clip. Connect fresh air intake hose to acoustic cover and tighten clip screw.
  23. Fill JATCO A/T with fluid. See JATCO A/T - DRAIN & REFILL  under DRAIN & REFILL PROCEDURE.
  24. Connect battery negative cable. See DISCONNECTING & CONNECTING BATTERY  under SERVICE PRECAUTIONS. Refill cooling system. See DRAINING & REFILLING COOLING SYSTEM in ENGINE COOLING article.
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