LT230R Leak Diagnosis

[Dougal]

I have some leaks and I'd like some opinions on the most likely suspects.

Here is a picture of my LT230R, just removed. It was installed completely clean with new seals about 2 years ago, covered 15-20,000km since.
For 10,000km of that it was leak free, then it had a spectacular first oil leak followed by continual dripping (leave a 5cm puddle when parked kind of dripping).

https://www.aulro.com/afvb/images/imported/2010/07/660.jpg

Suspect A is a given, the flange is quite clean but I suspect it would be as dust can't get in easily to make the mud which forms elsewhere.
How about B and C.
B is the hi-lo range lever. I suspect this one because the oiley mess is spread so high and it's clean.
C is the intermediate shaft. I think it's only showing oil coming down from B.

The front shaft seal is also seeping (brand new seal which slowly bled oil from day #1) but the oil from that stays underneath. Notice that's a seep, not the leak I'm hunting.

[windsock]

Hi Dougal,

How you going? I have had a seeping leak from C in the past. Pulled it apart to replace the main seal (A) as that is where I thought it was coming from but I saw signs of seepage from C. A bit of hi temp gasket silcone seems to have worked well. The truck is back to leaving the usual drip once in a while now.

Cheers,

Phil

[Dougal]

Hi Dougal,

How you going? I have had a seeping leak from C in the past. Pulled it apart to replace the main seal (A) as that is where I thought it was coming from but I saw signs of seepage from C. A bit of hi temp gasket silcone seems to have worked well. The truck is back to leaving the usual drip once in a while now.

Cheers,

Phil

Thanks Phil, there'll be a liberal amount of sealant put around these parts just-in-case on reassembly. At least that way I'll know next time where the oil hasn't come from.

I'd really like to put bikes on the back without worrying about oil all over the disc rotors.

[Bush65]

Leaks from 'c' are fairly common.

Even though the intermediate shaft does not rotate, it moves enough to wear the housing.

When this happens the only reliable fix is to machine the housing out an fit a steel sleeve. It is a common modification.

Since you have the box out, push the intermediate out using a dummy shaft to retain the gears in position. Then you can determine if the housing is worn or if the o-ring was leaking.

[Dougal]

The correct answer was "all of the above".:eek:

Looks like the box sat for long enough before I got it for all the orings to go hard.
The two orings on the hi-lo selector are the tricky ones, the case around the intermediate shaft appears fine, just hard orings which have stayed flat and don't seal anymore.
The design of the intermediate shaft seals is quite nice, the shaft only needs pulled about 1 inch out and both orings can be changed. The front case stays on, it could be done on the car if you pulled the transfer back an inch and had Z shaped fingers.

[jackerz]

I have some leaks and I'd like some opinions on the most likely suspects.

Here is a picture of my LT230R, just removed. It was installed completely clean with new seals about 2 years ago, covered 15-20,000km since.
For 10,000km of that it was leak free, then it had a spectacular first oil leak followed by continual dripping (leave a 5cm puddle when parked kind of dripping).

https://www.aulro.com/afvb/images/imported/2010/07/660.jpg

Suspect A is a given, the flange is quite clean but I suspect it would be as dust can't get in easily to make the mud which forms elsewhere.
How about B and C.
B is the hi-lo range lever. I suspect this one because the oiley mess is spread so high and it's clean.
C is the intermediate shaft. I think it's only showing oil coming down from B.

The front shaft seal is also seeping (brand new seal which slowly bled oil from day #1) but the oil from that stays underneath. Notice that's a seep, not the leak I'm hunting.


how long did it take you to remove this?

my leak is coming from one of those! :(

[Dougal]

how long did it take you to remove this?

my leak is coming from one of those! :(

To get the box out was probably 3-4 hours work. I made up a wooden jig to support the case on my jack, unbolted everything then had to wind the case off the input shaft as it's a very tight fit.

Replacing the seals I found the front output shaft seal was in very tight, the intermediate shaft seals (C) were easy as on this box the shaft slides out the back 2 inches giving access to both orings.
The linkage orings were difficult, I had to file high spots off the shaft before it would slide back out the housing. Once I had the shaft out I had to clean it up on a lathe before it was a nice fit in the housing.

The input seal I reinstalled on the shaft and slid the transfer up onto it. I also installed a polyurethane sandwich seal which fits between the gearbox and transfer case to prevent oil leaks between them and provide proper location of this transfer input seal. It has worked well as it hasn't leaked, seeped or dripped since.

[Blknight.aus]

you can do the intermediate shaft with the box in place providing you come down from the top through the seatbox. but as its unlikely to be the only thing thats leaking you're usually better off pulling the case and fixing all the leaks in one hit.

[It'sNotWorthComplaining!]

how long did it take you to remove this?

my leak is coming from one of those! :(
Interesting to see you have an oil filler on the top of the case instead of the usual upper rear

[Dougal]

Interesting to see you have an oil filler on the top of the case instead of the usual upper rear

Yes and it's very handy too. Provided you don't spill any oil inside the vehicle while filling.
This is only on the 1983 made LT230R. My 1985 LT230T doesn't have the top fill either.