Thread: Leaking Gearbox/transfer case

Originally Posted by MW.TD5 Defender

I have had a small leak!! from either the TF or GB for quite some time but over a recent trip it has got really bad. but not sure from where.

I checked GB & TF. Some days I had to put oil into the GB, approx 40-50ml
Other days Oil I would remove the filler plug and oil would pour out of the GB and I had to put oil in the TF case.

The last fill was to the TF case and approx 300ml

The under side and back of the car is coated with oil.

My question is why did I put oil in the GB sometimes & other times the TF case?
Seems like oil is transfering between the two ?

Is there an additive I can add to slow down the leak until I can get it repaired?

I will change the oil in both as the oils are probably a mixture now.

thanks in advance

Mal

Sounds like the seal between the gearbox and transfer case has had it its a remove tc job

Originally Posted by rangieman

Sounds like the seal between the gearbox and transfer case has had it its a remove tc job

yeah, but they are two separate seals

Could be t/case input shaft seal or the intermediate shaft O rings. Pretty common. When the t/case is out, do both.
As I mentioned in the g/box thread running ATM, make a couple of locating pins for re-installation from some long 10mm bolts with the heads cut off and a slot cut in them. Should be 170mm+ long.

The gearbox extension housing/output shaft seal is a bugger. (if it's leaking) In theory the seal running collar is a press fit on the shaft and a special tool is needed to remove and install it to install the seal. I cheated and made a tool that I placed the seal on that slid over the collar to install the seal in the extension housing, then the tool was removed. You can't do it this way if you use an aftermarket double lip seal, it will only work with an OE seal. BTW, this seal is Viton and should last a long time.