ird woes.... please help

hi guys...
you guessed it.. i bought a freelander, after a few weeks and a bit of reading up i suspected the viscous coupling was shot...
got it in at my mates garage, the plan was to change the vc and do a thorough service.......
it didnt quite go to plan........... doh!!!!!!

we removed the prop and vc unit but on closer inspection the bearings in the ird output seemed a bit poorly notchey ? the pinion etc seems fine though..i think ive just caught it before the whole thing went bang.....:doh:
luckily my mate is a gearbox specialist so all that is in hand...

were im stuck is the oil drain plug on the ird..... it has NO thread !!!
the car was previously serviced by Landrover and this must have been done by them.......
when we wound it out it came out quite stiff... all that was left of the thread was some bits of swarf !!
so, other then trying to find a casing, does anyone have any other idea's ??
i think with the verniers the plug was aprox 22mm dia.... not sure weather i can get a larger one and tap the case etc or if theres some kind of mandrill kit etc..........

man im annoyed at the bag of crap i bought.

Not sure how to fix your problem but these part numbers may help. They’re for my v6’s IRD:

IRD filler plug TRL100060
IRD filler washer TFY101060
IRD drain plug TAS100000
IRD drain washer TFY101070

cheers hippo..
still open to suggestions...

Did you see that episode of the garage when Jock had to get sleeves machined, internal and external threads, for cylinder head bolts.You might be able to do something similar.You really got fugk'd in at the deep end.

A Helicoil insert is probably the answer...

yes, im thinking of heli coils route.....
i dont suppose anyone could tell me what the size/thread of the origional is ? mine is obviously goosed..hahaha..

thrown in at the deep end is an understatment mate... ive heared all the horror stories of freelanders, this one, allthough very tidy, one owner full history,low miles, seems to have caught me out..................
im really hoping that once ive sorted the vc and ird issue that should be the end of my troubles for a long while.... god knows if this car kicks off with any other issues i may have to get shut and mark my landrover experience as a plain wrong un'....

today i we did, decompression filter ( engine breather?) which i believe is a good thing to be on top of... oil/filter, air filter/ pollen filter/fuel filter..... the prop is stripped off ready for the new viscous coupling to go on and ive got it booked in for next wednesday to have the ird removed split and all its bearings/seals renewed.....

the only outstanding issue is that bloody oil filler plug hole on the ird....???

if any one has any other suggestions for preventative maintenance for me to be on top of, please let me know............its an 05 plate TD4 with 40k on clock...

or cut a new thread and fit a larger plug, or bolt instead

find out what the tapping size is for a 1/2" bsp or npt thread, these are tapered threads and plugs are easily obtainable from engineering places, can't remember sizes off hand but if you measure the bore of the hole as it is now and let me know i'll check my zeus book and tell you what you need, easy fix really.