IRD and drill bit woes

I was getting a rumbling/groaning noise from the transmission/running gear so upon reading a couple of posts on here decided to remove the propshaft. This cured the noise that appeared to be coming from the ird and so as we were due to tow a caravan on the coming weekend I decided to drain the oil from the unit and put new in it with molyslip, so far so good.

I had previously topped up the IRD just after buying the vehicle as there is a slight leak from the driveshaft oil seal and so I drained the unit without checking if the top up plug would undo. You can probably guess what happened next, the dam plug would not undo and as I was using quite a long extension bar to get to it , it was a right cow and eventually started rounding off. Cutting a long story short I was left with no option but to drill it out bot using a pilot drill and working up in size until it was weaken enough to chisel it loose. Upon getting to 8.5mm the dam drill bit went through unexpectedly and snapped about an inch off. Gutted I carried on increasing the size of the drill and finally got it off.

How in gods name am I going to get that snapped bit out? I have borrowed my brother in laws scope he bought in Lidl but it really isn't up to the job. Is it possible to remove the end of the IRD where the driveshaft locates as I notice it is bolted together there as I really don't fancy removing the whole unit

If you were to open the IRD, I think you'll need to remove it from the car. I cant remember exactly, but there's at least 8 bolts holding the 2 bodies together - and I'm sure you'll have bad access to a couple of them. Also mine was a bugger to split, the 2 bodies really didn't want to separate. I was whacking it quite a bit and it didn't budge. In the end, I 'happened' to leave it in the sun, it got warm/hot, and separated quite easily.

If you split it, you're basically disassembling it, and should probably use a new seal on the driveshaft output- might cure your leak if its that end!

I've forgotten what the inside mouldings are like as to whether if you flushed it the bit would end up around the drain plug - might do. Once again, you'll probably have better luck with the unit off the car so you can turn it and move it around.

If the unit is suspect, might it be worth getting a recon unit if you've got to go to the trouble of getting it off, split it, and get it back on again.

I don't really want to take the unit off just yet as it's a bugger of a job, esp on a driveway. I have a spare unit but I have no idea if it's any good as it's off a spares or repairs freelander the the guy I bought mine off had. The drain plug isn't a clean hole as it's has a sort of stepped profile so there's no way it's coming out that way. Tomorrow I plan on getting a sealey flexible magnetic pickup tool

Sealey AK6531 Flexible Magnetic Pick-Up Tool 1.5kg Capacity - Pick-Up Tools Magn | eBay

in the hope that it will work. I have even thought of using a Neodymium Magnet on the outside to try and move the drill bit nearer the top up hole. desperation perhaps but my wife and I were supposed to be caravanning on the coming weekend and there's no way I could remove the IRD and replace it by then.

I have one of those - very useful for collecting stray sockets even if you can't see them!

If you're in a hurry ASDA sells something similar (ours does anyway), so do Halfords for twice the price.

I hope you get lucky!

What about any swarf from drilling that may have got into the box ?????

order the plug first as LR agents do not keep them in unless you are lucky, what about a magnet is not the box alloy so it will not stick to that and hopefull you will get any swarf out as well ,where about are you .If I am close It is possible I could help. some screw drivers are magnetic or if you do not have a magnetic one but have a magnet then keep rubbing the shaft of the screw driver across the magnet from one side to the other this will magnetize it or just keep the magnet on the screw drive
hope this helps

If your filler bolt is rounding, get yourself a set of Irwin Bolt Grips - they'll undo it for you, although you'll still need a replacement.

As above with Teddy, if you're local to me in Dorset give me a nod as I have a set of Irwins and a couple of magnetic flexi-tools.

First of all thanks for the replies and advice. I have got the drill bit out and I can tell you I'm chuffed . The flexible magnetic pickup tool I bought was to big to get past the gears and I though I was buggered. As a last resort I made a tool out of a telescopic magnetic pickup tool and some wire and at the first attemp I got it past the gear into the sump area and eureka one broken drill bit attached. see pics Oh I thought I should add I have a spare unit so I used the plug from that.

Fantastic, you must so relieved, now you can concentrate on getting ready for your caravan trip.

Yes thank you I'm very relieved , and probably more to the point, my wife is a lot happier .

As for the swarf mentioned earlier, I used copious amounts of grease when I was drilling to make the swarf stick to it instead of falling in the unit. I also fished around with the magnet and got a small amount out and lastly I filled it with 10/40 drove around the block and then drained it thoroughly before putting in some molyslip and the correct oil.

Thanks for the Irwin Bolt Grips suggestion, I hadn't heard of them and they are definitely on my shopping list.

Clever. Great result. I'd give the unit a flush through to get any remaining bits out (and swarf).

Maturecheese said:

Yes thank you I'm very relieved , and probably more to the point, my wife is a lot happier .

As for the swarf mentioned earlier, I used copious amounts of grease when I was drilling to make the swarf stick to it instead of falling in the unit. I also fished around with the magnet and got a small amount out and lastly I filled it with 10/40 drove around the block and then drained it thoroughly before putting in some molyslip and the correct oil.

Thanks for the Irwin Bolt Grips suggestion, I hadn't heard of them and they are definitely on my shopping list.

Click to expand...

I've got a complete set - they're awesome.

Great job getting that drill bit out! A classic diy story - this will take me an hour to fix at most ...... several days later ............
I do like the look of the Irwin bolt grips. I have the same undo-able IRD fill plug problem as you and they might save a lot of trouble.

well done :5bhurray::5bhurray: