leak between transfer case and gearbox

**Ace** · 1st September 2007, 06:16 PM

Hi all, i removed the transer case last year to replace the o-ring on the end of one of the shafts that was causing a rather large leak, having done that 3 weeks after it went back in its now leaking from between the two, i am not sure but i think i may have damaged the shaft seal that stops oil moving between the two. I am pulling it all out to fix the leak and put a new clutch in at the same time so i can put the transer case and box back together on the floor before it all goes in so i dont damage the seal again. My question is, is there something else i can do to stop the leak from coming back after a few weeks as i am told this is a common leak. The box and TC go together metal to metal with no gasket, could i put a small amount of gasket sealant between the two just to make a it better seal? Or are you not supposed to do that?

**rick130** · 1st September 2007, 08:37 PM

did you use a couple of guide studs when reassembling ?

get a couple of (10mm?) bolts about 170-200mm long, chop the heads off and saw in a slot and screw them into the back of the g/box before reassembly, then slide the two together and bolt up. (and unscrew your guide studs

)

**Blknight.aus** · 1st September 2007, 09:14 PM

check that the bearings are holding the shaft true as if it wobbles it can turn the 2 seals into pumps that push the oil out..

And ricks idea is a good one but to go it one further on your guide bolts once youve cut the heads off grind a couple of flats opposite each other so you can get a good grip on them with a shifter, open ended spanner or pair of pliers.

51jay · 2nd September 2007, 12:47 AM

The manual actually specifies using guide bolts when removing and replacing the transfer box

**Bush65** · 2nd September 2007, 07:42 AM

There is a groove in one of the joint faces (LT230 from memory) to let leaking oil escape.

Either the gearbox seal or t/case seal can leak. Both run on a bush that is a press fit on the gearbox output shaft (I'm not familiar with the arrangement with auto's). If the seal surfaces of the bush is worn or damaged, it should be replaced (can be difficult to remove - it has a circumferential groove to suit a puller).

As well as using studs for reassembly, it is worthwhile leaving the input gear out until the LT230 is bolted up to the gearbox. However this is not possible with all ratios.

**BigJon** · 2nd September 2007, 10:39 AM

We have now taken to sealing the join between the gearbox and transfer case. Not so much to stop oil from leaking out, but to stop sand / dirt from getting in. In our experience, contaminants get in and damage the seals.

**Ace** · 2nd September 2007, 08:05 PM

Originally Posted by BigJon

We have now taken to sealing the join between the gearbox and transfer case. Not so much to stop oil from leaking out, but to stop sand / dirt from getting in. In our experience, contaminants get in and damage the seals.

What have you been sealing them with Jon? Just gasket sealant?

Thanks for the replies guys, i will use the guide bolts this time, i dont want to do it a third time. I will inspect everything or wear aswell, everythig seemed pretty good when i did it last year. Matt

**rangieman** · 2nd September 2007, 08:09 PM

Originally Posted by Ace

What have you been sealing them with Jon? Just gasket sealant?

Thanks for the replies guys, i will use the guide bolts this time, i dont want to do it a third time. I will inspect everything or wear aswell, everythig seemed pretty good when i did it last year. Matt

Silicon is fine matt

**Ace** · 2nd September 2007, 08:53 PM

Originally Posted by rangieman

Silicon is fine matt

so chewing gum is no good

**Ace** · 2nd September 2007, 08:58 PM

Originally Posted by BigJon

We have now taken to sealing the join between the gearbox and transfer case. Not so much to stop oil from leaking out, but to stop sand / dirt from getting in. In our experience, contaminants get in and damage the seals.

does sealing them up mean that the oil can become trapped between them? Would this cause any problems?

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