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200tdi transmission brake/transfer box seal


cactus jack
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:blink: I have a leak comming from the transfer box seal into my handbrake drum. I also note that there is a clunk when changing gear. From underneath, I grabbed the rear propshaft and can hear the clunk comming from the transfer box near the handbrake drum. Is there anything I should look at while I am changing the seal which could be causing the clonk?????

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yeah, the input shaft from the main gear box... the splines are nut lubricated properly on 200Tdi's and can wear... causing the clonk you can hear/ feel...

if you take the PTO cover off, then remove the bearing support (2 big screws) you can withdraw the transfer box input gear and inspect it... if its dry inside, and full of swarf, its new gearbox time.... if its on the way out, the splines will look worn on one side...

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yeah, the input shaft from the main gear box... the splines are nut lubricated properly on 200Tdi's and can wear... causing the clonk you can hear/ feel...

if you take the PTO cover off, then remove the bearing support (2 big screws) you can withdraw the transfer box input gear and inspect it... if its dry inside, and full of swarf, its new gearbox time.... if its on the way out, the splines will look worn on one side...

Thanks for the advice. Is this easy to inspect and how long will it take?, where is the PTO cover, and do you mean that I need a new gearbox or transfer box? If I just do the seal, will it stop the leak so that I can hold out for a while?

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I think the leak and the clonk may be two separate issues...

unless a bearing has failed, causing a clonk, and a leak.

I did mean gearbox, the output shaft from the main gearbox is what wears away.. as the splines are not lubricated where it enters the transfer box, later disco's (300tdi) had a cross-drilled input gear in the transfer box which splash-lubricated the mainshaft..

the PTO cover is the round disc on the back of the transfer box, it has either 6 or 7 bolts holding it on...

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I think the leak and the clonk may be two separate issues...

unless a bearing has failed, causing a clonk, and a leak.

I did mean gearbox, the output shaft from the main gearbox is what wears away.. as the splines are not lubricated where it enters the transfer box, later disco's (300tdi) had a cross-drilled input gear in the transfer box which splash-lubricated the mainshaft..

the PTO cover is the round disc on the back of the transfer box, it has either 6 or 7 bolts holding it on...

Ok, thanks. I think i will do the seal first, so that I have dry brakes for the m.o.t and let the other problem develop or until funds allow.

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