Major Transfer Case Leak

**Gaudough** · 17th September 2011, 06:14 PM

The TC has been leaking at the back to back seals for over 100,000kms and I regularly check the state of the leak and the oil level. Only last week I checked and topped up with 100ml of oil. The TC crossmember did seem slightly wetter than normal but with only 100ml needed over the last 2000kms I was not worried.
Well, got home from a 20km drive down the Bruce Hway this afternoon at 110kmh and found a lot of oil spots on the rear of the Disco. A quick look underneath shows oil everywhere and multiple drips hanging from the crossmember.

Okay its time for that rebuild I have been putting off.

So after dinner I crawl underneath to have a look and what do I find..well at least 500ml of gear oil on the garage floor which definately looks bad. At least I know it had that much oil in it when I was driving.

One of the gearbox to transfer case bolts just hanging on by a thread, about to fall out. How good is that, I can put off the rebuild for another few kms just by putting the bolt back in.

The Disco has done 290,000kms so I am sure it will need more than a seal when the time comes.

**justinc** · 17th September 2011, 06:20 PM

You are lucky, that bolt is not a blind hole and goes straight through to the oil chamber. They have to be installed with thread sealant to prevent leaks.

Buy a lottery ticket.

JC

**Gaudough** · 17th September 2011, 06:46 PM

Originally Posted by justinc

You are lucky, that bolt is not a blind hole and goes straight through to the oil chamber. They have to be installed with thread sealant to prevent leaks.

Buy a lottery ticket.

JC

Thanks Justin, yes I assumed this bolts holds the oil in. Will check all the others around there as well.

Gordo

**justinc** · 17th September 2011, 07:10 PM

The only other one that will leak if not sealed is the bolt directly above that one. All the others go into a blind hole.

JC

**Gaudough** · 17th September 2011, 07:29 PM

Justin, what do you suggest as sealant. I was thinking of draining the rest of the oil, cleaning up the hole and bolt with brake cleaner and using loctite.

Gordo

**justinc** · 17th September 2011, 07:34 PM

Originally Posted by Gaudough

Justin, what do you suggest as sealant. I was thinking of draining the rest of the oil, cleaning up the hole and bolt with brake cleaner and using loctite.

Gordo

We use Wurth Hydraulic thread sealant, but a medium strength loctite would work fine.

As you mentioned, brake cleaner and some compressed air to dry it out first.

You are 1 lucky individual!

JC

**Gaudough** · 17th September 2011, 07:51 PM

Originally Posted by justinc

We use Wurth Hydraulic thread sealant, but a medium strength loctite would work fine.

As you mentioned, brake cleaner and some compressed air to dry it out first.

You are 1 lucky individual!

JC

Thanks, I have had really good luck with Discos.

Had leaks appear a week before leaving on big trips a number of times.

Most faults show up in the garage, like this one.

I was so glad to see 500ml or so of oil on the floor after I parked it in there. Meant it wasnt dry.....

Gordo

**Gaudough** · 18th September 2011, 03:23 PM

All fixed, I drained the remaining oil, cleaned up the bolt and hole, reassemble and refill and all good.

There was still over 1L of oil in the TC so I think I got it just in time.

1 of the other bolts could be nipped up but only marginally, all the others I could get to were tight.

Gordo

**feraldisco** · 14th October 2011, 02:34 PM

Hi - I know I the drive flange seal can be a problem with D2s and result in oil leaking from transfer case into handbrake drum, but I think I've solved this problem and still have a leak at the rear - is it common for the rear transfer case seal itself to leak? That looks like a bit more of a major job...

**DassaW** · 10th December 2011, 09:49 PM

Gday,

I have just noticed that the t/case on our D1 has just started leaking too.

Just wondering if there are any other likely places that it could be leaking from other than those bolts? We are travelling around OZ and have done about 20k km in the last 4 months, so I found it starnge to have just happened now.

I will check the tension on those bolts in the morning, but should I be checking anything else? Its a bit hard to see exactly where the leak is coming from.

I checked the oil level before and it is only down about 10mm from the filler hole, so it will be fine for now, but would like to get it sorted.

cheers

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