IRD refit issue

Hi all,
2005 Freelander 1 1.8,
I removed the IRD before removing gearbox to replace clutch, all brackets and mounts are off.
Issue now is on refitting IRD it will go in with about 1/2" to go (just shy of the O ring about to go in) then stops. I have rotated o/p shaft flange, drive shafts and engine flywheel but nogo. It has engaged first splines as rotating o/p flange causes drive shaft splines to rotate - gear box in neutral.
As I tighten the 4 x IRD to gearbox bolts the rotation becomes tight to stopping so did not progress in fear of breaking something.

Any ideas thanks?

I had the exact same issue when I changed my gearbox. There are two sets of splines that need to line up. Put the IRD in as far as you can get it and put the bolts in hand tight. Put the car in gear and using a spanner or socket slowly turn the engine over on the bottom pulley bolt. I saw the IRD give a slight kick when the second set of splines lined up. Try tightening the bolts again to draw it on.

I don't think I put any bolts in until the IRD was pushed flush up to the gearbox (plate). That way I could rotate the IRD a bit to help the splines mate up. Took a few goes, and a few naughty word probably cos it ain't the lightest piece of kit even if the trolley jack was supporting the weight - but it did go in. Then put the bolts in and tighten them.

Even with the splines lined up I couldn't push it in the last half inch or so. Just doing the bolts up pulled it in easily. Guess I'm just a weakling. I was working on it lying on the floor mind and had hardly any room to move. I had it up on axle stands. I wish I had a proper lift.

I wouldn't do it on axle stands - it would be much to hard.

I'm lucky in that I've got an inspection pit. I lined the IRD up over just in front of the pit so I could use the trolley jack on it and just needed to lean over a little bit, access was really good. It did take quite a bit of wiggling though before it went in - that sounds rather rude!

I find fitting the complete NS assembly so the wheel can be turned manually, really helps line up the splines.

Thanks all, you know when the secound set of splines are in as both drive shaft splines and o/p flange are linked (first set in they can all rotate independantly). Its at the point when the polished aluminium sleeve of the IRD goes into the gearbox (the magical last 1/2").
After offering up for the third time at 10:00pm the red mist came down and after much aggrevated pushing, twisting and rattling it went in!

Well done

See, as with all these things - its the naughty words that get the job finished.... or what ever your working on destroyed!

You must all be rubbish, mine went in easy, therefore I must be superior.














Or just a lucky b@stard!!!!!