Starting dismantling the gearbox. Mostly it is in good condition. All the seals have the flexibility of a piece of aluminum, certainly not rubber.
Found the oil leaking from the bell housing problem, the oil pump housing bolts were finger tight.
The main pinion bearing has a lot flex in it so I think the lack of oil in the box overall and no/low oil pressure to the main bearing is my main problem.
Found metal fillings in the bell housing, I think it is from the hole cut in the top of the bell housing.
I have thought long and hard as to why someone would cut a hole in the bell housing. All I can come up with is same dumbo that cut the side gates had another bright idea. Perhaps to boodgy the thrust bearing clip with a bit of lock wire.
The only other damage I can find other seals and bearings is the CDL locking mechanism on the diff end. I don't think it will be a problem as the shifted lock gear sit on this all the time, makes me wonder how it happened though.
The front output shaft bearing seems pretty flogged so I think the front drive shaft has taken its toll. This would not be too hard to change with it in the vehicle if you had to.
So now I all need to do is build up the courage to change the main gearbox bearings myself.
All this months pics are here - LR101FC - Progress November 2009
Peter


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