Thread: LT230T transfer case intermediate gear question.

Originally Posted by Nomad9

Hi Forumites,
The intermediate shaft o-rings have started leaking so I've now removed the gearbox. The next step is to replace the o-rings the intention isn't top strip the whole transfer case down and replace everything. The transfer case was fine just leaking an annoying amount of oil.
Thankfully the manual tells me that the intermediate shaft is the first to be removed from the transfer case when being stripped. The assembly of the intermediate shaft requires special tools and other things I don't have. Is there a "layman's" approach to this repair, do I have to fit a new collapsible collar, I know I should really. All I need to do is replace the leaking o-rings.
I'm just trying to get a feel for the job before I dive into uncharted waters. Any constructive comments welcomed.
Thanks in anticipation.

G'day Nomad,
I have a workshop manual for this box. PM me if you need and I will photocopy the relevant bit for you. Not a difficult job and could have been done with the box in the vehicle.

Hi Brian,
The engine is out for a rebuild, I'm waiting for the block to come back, got bored so it was fairly easy to just drop the box out.
I'll PM you, if you could photo copy the relevant bit that would be great, thanks for the help.

IME leaks from the intermediate shaft are usually due to the hole in the case being worn/ovaled.

This will usually require the box to be stripped so the intermediate shaft hole can be bored and sleeved.

Apparently this is caused by too little preload on the intermediate bearings.

MR Automotive in Brisbane sleeve the cases. I would like to find someone in WA who can do it for a reasonable price.