robmurg Posted August 20, 2014 Share Posted August 20, 2014 I recently noticed that the transfer box (LT230) on my ex-military 110 was using oil. After topping it up a few times I realised that as the level in the transfer box drops, so it rises in the gearbox (LT77). I assume transfer box oil is leaking into the gearbox while on the move (it dosen't seem to happen while standing for a few days). Can anyone advise how this might be happening and how to fix it please? I've searched the forum and technical archive and found nothing that seemed relevant. Thanks! Quote Link to comment Share on other sites More sharing options...
Eightpot Posted August 20, 2014 Share Posted August 20, 2014 Worn seals on the gearbox output and transfer input allowing oil to get across- though I'd have thought it would just escape out through the joint between the boxes first. Easy to change the seals once the transfer box is off. Quote Link to comment Share on other sites More sharing options...
ejparrott Posted August 20, 2014 Share Posted August 20, 2014 Worn seals on the gearbox output and transfer input allowing oil to get across- though I'd have thought it would just escape out through the joint between the boxes first. Easy to change the seals once the transfer box is off. Probably means the two have been glued together so the oil can't escape.... Quote Link to comment Share on other sites More sharing options...
dave88sw Posted August 21, 2014 Share Posted August 21, 2014 Worth checking the ends of the breathers where they come up in the engine bay, often the ends touch the engine/manifold and get melted closed, then the box pressurises. Quote Link to comment Share on other sites More sharing options...
robmurg Posted September 7, 2014 Author Share Posted September 7, 2014 Thanks everyone for the avice, which all makes sense. I'm following the excellent guide from the technical forum by White90 and trying to remove the transfer box. I've reached the stage where I remove 4 bolts and the nuts from 2 studs that seem to be all that holds the transfer box to the gearbox. I've supported the weight of the transfer box but it remains firmly attached to the gear box. I'm not sure if I've a: Missed a bolt b: Not put enough force on to break the glue that ejparrott mentions or c: Something else. Help so far much appreciated and I will persevere! Quote Link to comment Share on other sites More sharing options...
Eightpot Posted September 7, 2014 Share Posted September 7, 2014 There are the main visible nuts on the rear of the box plus two at the front near the linkages If a load of sealer has been used it will take a bit of prising Part. Tap a flat screwdriver into the joint at the top and gently work it round as the joint starts to split. Quote Link to comment Share on other sites More sharing options...
robmurg Posted September 7, 2014 Author Share Posted September 7, 2014 Thanks Eightpot, reassured that I'd not missed a crucial bolt I moved on to the screwdriver technique which did the trick. A bit nerve wracking making sure to avoid damage. There's some black silicone on the mating surfaces that I guess I need to remove before re-assembly. The oil seal on the transfer box is in reasonable condition but was hanging loose on the shaft so I'll replace both seals before reassembly. Cheers, Rob Quote Link to comment Share on other sites More sharing options...
ejparrott Posted September 8, 2014 Share Posted September 8, 2014 Clean the silicone off completely, shouldn't be any there at all. Quote Link to comment Share on other sites More sharing options...
cackshifter Posted September 8, 2014 Share Posted September 8, 2014 I'd recommend the use of 180mm long headless bolts in the bolt holes for alignment when replacing, courtesy of http://forums.lr4x4.com/index.php?showtopic=6024 (Mine were quite tight so I drilled a hole across the ends as well as make a slot so I could use a small tommy bar), removal of input gear (less to lift and gives a place to grip, less chance of damage), and make sure the hi-low linkage connects before doing up all the bolts - easier to connect when the transfer box is just a few mm away from contact with the back of the main box; well it was on mine anyway. Quote Link to comment Share on other sites More sharing options...
robmurg Posted September 8, 2014 Author Share Posted September 8, 2014 Making progress, one step forward and two back. I've noticed that the old seals were fitted with the flat side inward, toward the oil. I was under the impression that the lip/spring side should face the oil? I'll try the headless bolt trick when re-fitting, thanks. For this evening I've ruined one of the seals trying to get it over the groove in the gearbox output shaft so now I've had to stop and order more and will be more careful when they arrive. Quote Link to comment Share on other sites More sharing options...
ejparrott Posted September 8, 2014 Share Posted September 8, 2014 I always thought it was flat side out, lip/spring side to the oil Quote Link to comment Share on other sites More sharing options...
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