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View Full Version : LT230 Output Flange Felt Spline Seals



Max Headroom 2.3m
30th January 2026, 08:10 PM
While stripping down my LT230 (prefix 43D) on my 2004 TD5 Defender 90 (South African built), I removed the front and rear output flanges and came across something beyond my knowledge base (that's not hard!![tonguewink]). The transfer case has only done about 75,000km and I am certain it is stock standard original from factory.
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The felt spline seals that go under the thick metal washer and M20 Nyloc nuts appears to have been soaked in a brown waxy substance that has a pleasant sweet smell. I don't think it is PTFE based but I could be wrong (there is always a first time....[biggrin]). The waxy substance has also crept up into the splines and onto the shaft thread so I am guessing it was quite runny when first applied, probably by soaking the felt washer before installation. The wax is firm at room temperature but I can easily press my nail into it. It appears not to be soluble in mineral turps or transfer case oil which would make sense.
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As a seal to prevent transfer case oil leaking out of the splines, the waxy substance has worked a treat and the flanges were easily removed once the nuts were undone. Of course, now I would like to replicate this seal but I am not sure what product was used. I am not keen on using the often recommended Loctite Retaining compound (or similar) applied to the splines to seal them as I would imagine the flanges will be very difficult to remove at some point in the future. I have a similar concern about using silicone or polyurethane goo sealants.
Anybody have any ideas what the brown waxy substance might be?

workingonit
31st January 2026, 01:42 PM
The felt spline seals that go under the thick metal washer and M20 Nyloc nuts appears to have been soaked in a brown waxy substance that has a pleasant sweet smell.

Hylomar?

Max Headroom 2.3m
31st January 2026, 02:31 PM
Hylomar?

Good call but then the question is which Hylomar product? There seems to be about a dozen grades. Most of them appear to be a blue colour and designed as non-setting jointing compounds. I will contact Hylomar in the UK and see what they think. The only Hylomar product I am familiar with is Hylosil 100 Series which are silicone sealants.

350RRC
31st January 2026, 03:08 PM
It could be something like Permatex Aviation Form-A-Gasket Sealant liquid.

I't's brown , smells sweet and never completely hardens.

DL

Max Headroom 2.3m
31st January 2026, 03:50 PM
It could be something like Permatex Aviation Form-A-Gasket Sealant liquid.

I't's brown , smells sweet and never completely hardens.

DL

I have not used Permatex Aviation Form-A-Gasket but looks to be very similar to Loctite MR5923 Aviation Gasket Sealer which I have used (good stuff), going by the MSDS Data sheets. They are both Rosin based (a resin) material which is soluble in alcohol and is a dark opaque brown colour. The stuff on the felt seal I have is a translucent very pale brown (possible colourless originally but discoloured with time/use) and is not soluble in alcohol (just tested it). It also feels a bit slippery as though it contains a PTFE product but again, I can't be sure of that bit.

workingonit
31st January 2026, 07:00 PM
Good call but then the question is which Hylomar product? There seems to be about a dozen grades. Most of them appear to be a blue colour and designed as non-setting jointing compounds. I will contact Hylomar in the UK and see what they think. The only Hylomar product I am familiar with is Hylosil 100 Series which are silicone sealants.

My bad. Had a closer look at the decades old bottle to find it is 'Loctite 3' an aviation gasket glue, brown, and certainly not sweet smelling.