Tfer case leak

[juz63]

Hi all, My major problem is a lack of knowledge. Lesser problems include a lack of know how and a seriously low level of wherewithal. Spent many hours looking for the right info - lots to help but none quite the right thing. To business - leaking t/fer case (TC).- I believe that I have discovered the culprit but would like someone to confirm the anatomy of the TC for me. The leak seems to be originating at (what i call) the front of the TC- (G/box side). Bewtween the housing which has the front prop shaft on it and the g/box extension (where it joins to the TC).... sorry about my inadequate terminology :( I have followed the oil path up, and discovered that someone has smeared a large amount of silicone sealant at the top of this gap area - on the outside of the TC. Having read a lot of the forum messages and looked at my CD etc I can still not determine if this is the site of the dreaded intermediate shaft. This is my guess and if I am right the previous owner, has decided rather than fix it he'd do a bush job before selling. So, firstly could someone please tell me if this is the position of the inter shaft. Also, am I better off to take the removed TC to someone to have the shaft removed and consequently replaced? Thanks in advance for any help and sorry about long message.

[lambrover]

you only need basic skills to remove the tranfer case from the gearbox then remove the seal replace the seal and refit the tranfer case, make sure you surport the tranfer all the way off and all the way on so you don't damage the seal and you should be all right. get a workshop manuel.

[hubabajub]

mate from my recent experience with this problem, you are on the right track. from what you have described it is more than likely the o'ring that has gone or is going. im just about to have mine changed to the way is should have been when it was made. cost to get it done by someone who knows what they are doing is about 800..

[Blknight.aus]

your terminology and description is spot on.

the leak will more than likely be the seal as described and the cost given about par.

If you put you're location in the profile you might even be able to get in contact with someone in the local area who will help you and show you how to change the parts out.

[Gold_TD5]

Funny this should come up.
I had what I thought was a leaky TC but when I went to top it up, it was full.
When I checked the gear box, it took a litre;)
Since changing the gear box oil recently, the leak has all but dissappeared:)

Work that out:confused:

[Blknight.aus]

easy, the lastomer part of the newer oil has softened the rubber in the seal and its now doing its job again.

[Gold_TD5]

easy, the lastomer part of the newer oil has softened the rubber in the seal and its now doing its job again.

Thats what I was thinking but not using BIG words:)
Plus the car had sat for a while before I bought it in the middle of a QLD summer.

[jmkoffice]

Check the housing, where the intermediate shaft o-ring mates, as it may be out-of-round. No point fitting a new round seal in an out-of-round hole. The alloy TC case is soft and wears. To fix it properly, have a bush fitted so the I-shaft o-ring mates with the bush instead of the case. See the diagram for shaft and housing location. I had this done by MR Automotive in BrisVegas and they swear by it, as the bush is harder than the alloy.

Cheers

[juz63]

Wow! You guys are quick! Had to email and run last night so only just got back on line and here you all are with great advice. Cheers a million. Thanks for the thumbnail jmkoffice, that makes the position quite clear it's exactly where the huge glob of silicon is. Thanks also for the tip on price hubabajub, but to be clear is this just to have it ground and re-sleeved or to have someone do the whole job?
I wouldn't feel right presuming upon anyone to help with the job, but if someone has a tall garage space I could borrow for a little while (depends how long the sleeve etc takes) to do the job I'd be incredibly grateful - at least to the tune of a large bottle of your favourite! - The Deef has a tall box on the back about 2.3 metres from ground to top of the rack from memory (yeah, I'd love to chop it down and put a popper on it.. but that's another story) My garage door is about 1.8 metres tall and I'm so sick of working in the street. I'm in Reservoir in Melbourne. Lastly if anyone could suggest somewhere trustworthy to get the re-sleeve done I'd be very grateful.
Thanks again to all for once again incredibly helpful advice!:D justin.

[It'sNotWorthComplaining!]

Funny this should come up.
I had what I thought was a leaky TC but when I went to top it up, it was full.
When I checked the gear box, it took a litre;)
Since changing the gear box oil recently, the leak has all but dissappeared:)

Work that out:confused:

Most probably there was pressure build up in the gear box causing the leak, when you opened up the plug to fill, maybe the pressure equalized. Don't know if gear boxes have breathers?, maybe it was blocked:confused:

[Gold_TD5]

Most probably there was pressure build up in the gear box causing the leak, when you opened up the plug to fill, maybe the pressure equalized. Don't know if gear boxes have breathers?, maybe it was blocked:confused:
I'm guessing as it took a litre to top it up, it would have had a vacum if anything;)
I think it was more to do with the car sitting for a while in the heat.
I did about 10000K's before I changed the oil, just checking and topping it up every couple of weeks.
Got to the point it didn't take any at all:), so I lashed out and bought some semi synthetic gear oil and it's as good as stopped leaking.
When I first noticed the leak (after I had done a 1000K's or so, it was not leaking pre purchase) it got that bad it would not have passed a RWC.
I will pull it all out one day and give it the once over but for the moment it's all good.