Transfer case leak AGAIN?? surely NOT?? TD5

[occybruce]

g'day,

just noticed that it looks as if my transfer case is leaking oil again, after only being re-sealed around 12months ago-
SEE PICTURE ( its a 2003 cab/chassis defender td5)

Ive put a couple of arrows in to highlight where abouts the oil seems to pool and drip.

Its got me beat how it could be leaking from there ALREADY! and was hoping to get some advice before a friendly phone call

Roving Regards

Bruce

[goingbush]

Thats a really bad photo, apart from it being foggy it does not show where the leak is coming from, showing where the oil is ending up wont help the brains trust.

But my guess is that your intermediate shaft needs replacing and the housing needs a steel sleeve to stop it reoccurring, once the hole is flogged out you can seal it up all yo like, its going to start leaking again sometime soon.
I'd say you did well to get 12 months out of it.

[occybruce]

thanks heaps for the reply and apologizes for the **** poor photo "going bush",

apart from where its pooling on what i think is the bottom of the transfer case rubber mount i cant see where the actual source of the leak is.

the sealing and other works i had done previously was transfer case reseal, spigot bush ,clutch and fly wheel.. not sure if that had anything to do with the intermediate shaft and " once the hole is flogged out you can seal it up all yo like, its going to start leaking again sometime soon.I'd say you did well to get 12 months out of it"

how hard going is changing out the intermediate shaft and how long will i get out of it if its gone? good 200ks into town.

Regards

[goingbush]

Bit of a specialist job to do, but once its done and a steel sleeve fitted it should last forever. The problem is from the factory, the steel shaft flogs out the alloy housing.

If you can take the transfer case off it will be a lot cheaper, someone should chime in with a Transmission place that can do it for you, but it will probably be Sydney for you.

but you really need to find the source of the leak, before considering my opinion, if its coming from the front of the case between the gearbox and transfer case nose housing its probably the intermediate shaft seal

(the circle of the left below)

[landoman]

Thats a really bad photo, apart from it being foggy it does not show where the leak is coming from, showing where the oil is ending up wont help the brains trust.

But my guess is that your intermediate shaft needs replacing and the housing needs a steel sleeve to stop it reoccurring, once the hole is flogged out you can seal it up all yo like, its going to start leaking again sometime soon.
I'd say you did well to get 12 months out of it.

Think I have this problem with my 2016 110 …….how much should I expect to pay to get the machined sleeve solution and where in Sydney would one recommend to go to ?

[TonyC]

Think I have this problem with my 2016 110 …….how much should I expect to pay to get the machined sleeve solution and where in Sydney would one recommend to go to ?

Any of the Land Rover independents should be able to help.
Graham Cooper, Davies Performance Landys, KLR. There are probably others that the Sydney Siders will recommend.

The transfer case needs to come out, and be completely stripped down to a bare case, the case machined and the bush pressed in, then rebuild and refitted.

While I don't have a $ number it's not a small job.

Tony

[landoman]

Any of the Land Rover independents should be able to help.
Graham Cooper, Davies Performance Landys, KLR. There are probably others that the Sydney Siders will recommend.

The transfer case needs to come out, and be completely stripped down to a bare case, the case machined and the bush pressed in, then rebuild and refitted.

While I don't have a $ number it's not a small job.

Tony

Thanks for that …….if anyone has had this done and let me know how much I might expect to pay I would be grateful ……..

[discorevy]

how hard going is changing out the intermediate shaft and how long will i get out of it if its gone? good 200ks into town.

Regards

I wouldn't think Intermediate shaft is the cause in this case, as that isn't where they normally pool.

Above that spot is the detent for the high/low range which could leak if loose or not sealed, but that's really just a guess as well.

Whoever did the reseal should be happy to have a look next time you're there.

[DazzaTD5]

Just to add...

Defender TDCi (2007 - 2016) the retaining nut for the intermediate shaft commonly are loose as they were not staked enough from factory.
I guess this also adds to the wear in the housing.

The speed sensor is another common source of leaks.