Gearbox / Transfer Case Problems

[Hugh42732]

Hi everyone, just after some advice. Had seals (leaking) replaced in transfer case about 6 weeks/ 2000 km ago while still under warranty and now I feel I have major issues.

Since the work was done it had a slight whine when sitting on 100 k/h then on Monday morning it was hard to get into reverse and thought that Tuesday would be a slow day would look at it then. After a couple of hours was worse to get into reverse and when you did after reversing and putting foot on the clutch the wheels would lock up like you stood on the brakes also difficult to select second, so limped home and unloaded other vehicle reloaded gear I needed and left.

After talking to various mechanics as it was out of warranty dropped oil out of transfer case, well attempted to. Only got 1/2 a cup, if that, and lots of metal shavings and a few chips. When I dropped the oil out of the transfer case also noticed oil leaking from between transfer case and gearbox.

I was wondering if it's possible if the transfer case wasn't refilled could the gearbox oil to leak back into the transfer case (once the seals are buggered from being hot) leaving the gearbox oil low resulting in not being able to select gears.

Sorry for long post, any comments/advice/help/offers of new gearbox and transfer case appreciated.

Hugh

[strangy]

Interesting. If the transfer bolts were put back in the wrong spot, the transfer gears may have "machined" a bolt causing all the chips and initial tightness.

Cheers

[Hugh42732]

Hi everyone, dropped the Defender back to where the seals were put in and have had the transfer case removed.

"It appears to be a faulty seal that has failed resulting in the loss of oil" which resulted in the destruction of one transfer case and with no new LR ones coming into the country for another 60 to 90 days they have sourced a low Km replacement which is to be fitted with a 12 month guarantee.

My concern now is that they are not looking far enough, the seal in the rear of the gearbox is now leaking (actually dripping a little quicker than a drop/3 sec) and have been told that they will replace seal, flush gearbox and refill to proper level.

They are however not concerned as to why the seal has failed so quickly.

When the transfer case was out I had a look at the shaft that drives the transfer case and there was at least 7mm of movement up/down at transfer case end and 2mm front/rear, is this normal?

Hugh.

I also fail to see that if this movement is normal how the buggered transfer case would stop me from selecting gears.

Am I worried over nothing or should I be pushing to have the problem looked into further?