Thread: Oil leak between gear box and transfer box

1) I Havent done a TD5 but have done a lot of 4x4s in the past and I dont think that its a difficult Job. Unless there is something I dont know?
2) I personally think its expensive
3) Sorry I am no where you

There is an o-ring in the case of the transfer box that can be a problem. The o-ring from what I understand sits on a shaft and is held onto the casing. This ring will sometimes rotate overtime in the aluminium casing and makes a not so perfect seat for the next replacement o-ring.
Some dealers will tell you that they will replace the seals which may work for a few months then the leak returns.
What a lot of the dealers do is remove the transfer case and send it away to have it machined with a metal sleave for the o-ring.
I suggest that you go and see Award Diffs and Gearbox Services Rydalmere. Talk to him for some advice and methods of fixing and get a quote.
I have had my transfer box done and nil signs of leaking after 3 months.
It definately was cheaper than what you had quoted but without knowing exactly what is leaking go and speak to Terry.
David

My 84 RR with 4 speed and TC, had a pipe fitted between the fill plugs on both, the oil leaked internally, then returned via the connecting pipe. Simple. To check the oil, just checked the higher one, cant remember which.

Originally Posted by robert4wd

Hi All

my TD5 Defender has just been in for service at a dealers. They told me that there was an oil leak between the gear box and the transfer box. The quoted $1700 - $2000 to remove the transfer box and replace both rear gear box and front transfer box oil seals. This seems very very high to me. Three questions

1) How difficult is this repair - assuming that they have correctly pin pointed the source?

2) Is this a reasonable price?

3) Can anyone recommend a repairer who knows about defenders? I am located in the west of Sydney but will travel if the price/service is better.

Thanks in advance for you help

Robert

My dad is having the same problem with his td5 auto disco.
They want to charge him "an arm and a leg as well"
He lives in Melbourne or I would have done it in a weekend.

Originally Posted by rrturboD

My 84 RR with 4 speed and TC, had a pipe fitted between the fill plugs on both, the oil leaked internally, then returned via the connecting pipe. Simple. To check the oil, just checked the higher one, cant remember which.

That's a common problem on the Rangie 4 speed/TX case combo.........it pumps/leaks out of gear box and overfills the TX case.........I don't know about this "connecting tube" though - tell me a bit more about it please.

BTW - I was told by a long time LR mechanic that this problem is originally caused by putting wrong lubricant into this G/box and TX case and damaging the seals - they're supposed to run 20W/50 Engine Oil in BOTH!- NOT 80 EP in Gear box and 90 EP in TX Case as in the earlier 4 Speed G/Box /TX Case WITH LSD .....OR Dexron in 5 Speed G/Box and 90 EP in TX Case used with that....... with so many variations and combos it's easy to get it wrong and create your own set of problems.

It pays to double and triple check your basics specs and recommended lubricants etc till you're ABSOLUTELY certain it's the LATEST CURRENT recommendations for your particular Land Rover product!

Byron, the pipe was installed between the filler plugs. Both filler plugs were drilled and a 3/8 pipe soldered/brased into the plug, pipe clamped onto these. to check the level, necessary to unclamp the pipe (plastic/rubber oil line I think) then undo the filler plug. I sold the vehicle a couple of years ago, so cant take a snap for you.

You can only use a return pipe on a gearbox / transfer case combination that A: use the same oil and B: have a common 'back to back' seal.
The later Rovers with LT230 transfer cases don't do either of those things. As noted, it is often the intermediate shaft o rings, but the gearbox output seal or the transfer case input seal can also leak. We usually allow about 6 hours labour to remove and refit the transfer case while replacing all the appropriate seals and o rings. ($560 - $600 all up).

I think that intermediate shaft would be a good candidate for some Loctite bearing retainer during assembly to stop it moving in the soft housing and wearing the hole. But I suppose that by the time the O-ring leaks, the hole is too worn for bearing retainer to hold.