Thread: How clean/smooth do faces have to be on big LT95 'plate' gasket? Use blue goo too?

Just make sure there aren't any raised burrs that will prevent the plate from sitting down nicely. As long as the gouges don't go across the whole surface (from inside to outside) I'd just be installing with the gasket and a bit of Hylomar, but others might think differently.

Common place for them to leak is from the transfer selector shaft that goes right across the case near the top. There is a small oval shaped plate on each end held in place with 2 screws/bolts each side, and it retains a seal inside. Can't recall now if its a square or round section o-ring, but fitting 2 of them back to back has been suggested previously as a way to stop the leaking.
Leak from the LH one runs straight down over that main cover and would make it look like the cover was leaking, and if the box is hot and its not dusty there may not be much residue high up so have a good look.

Steve

Thanks for that Steve - If I wanted to check out the transfer selector shaft, how do I do that? From the top, by taking out the plate between the driver/passenger seat? Or can I get to it from underneath?

That blue stuff can be used without a paper gasket, it would fill any irregularities on the sealing surface. The flatter it is the less goo you would have to use.

go the goo

I will second what Steve has said there David, just knock any burrs off with a file, then a new gasket with goo.The main thing is to make sure you get all oil off the mating surfaces. As well as the cross shaft o rings there are 2 other possible leak areas. The rear output housing gasket and the filler plug. BTW the innards look very clean.

I pulled the plate off between the seats and it looks pretty dry on top:


Transfer lever circled, but not easy to see how it attaches.

I could be swayed to think that there is a leak on the opposite side to the transfer lever (drivers side), as it is a bit 'damp' up there, so perhaps it could be leaking down to the plate from above:


Am 99% sure it is not coming from the transfer case filler. All looks dry underneath that.

Steve - does the transfer selector shaft leak come from near the "M" in .com of this shot? :

That's the one. that oval plate that has the lateral shaft sticking out of it about 20mm. 2 bolts/screws in that, and a recess behind containing the o-ring seal/s.

Steve

Looks like a bugger to get to!! With the gearbox in the chassis anyway....