Transfer Box Leak, PAS Leak & Steering 'Issue'

Hey chaps,

Got 3 issues with my 2002 Defender 90 TD5.


#1 - Leak from the transfer box. This has always been there but never dripped enough to worry about. However last night I pulled up at a mates house stopped for all of 2 mins, engine off, and there was a noticable puddle underneath bout 10cm in size. I've put a pot underneath for the time being so I can measure how much oil I may be loosing.

First guess is output seal. I'll get a pic up tonight.


#2 - PAS has a leak. Dripping onto the steering arm, this one isn't too bad doesnt seem to loose a noticable amount but it deffinatley drips. Does need topping up on occasion. What needs replacing in here?


#3 - Steering judder - Possibly related to the above but im not sure. Since I changed the drop arm ball joint to the Disco type it was fantastic but over time my steering has gotten much worse. To the point where sometimes it doesnt even feel connected.

I also on occasion above 25mph get feedback in the steering wheel, the wheels wobble left and right then calm down. The tracking is correct, well as close as it can be, tyres are in good condition and I have a Terrafirma Damper fitted.

Where the Disco arm converson removed a lot of play I had in the steering it has come back, about an 1" or 2 either side where turning the wheel does almost nothing. Steering isnt heavy, infact it feels very light.

Could the steering pump be failing? Tyres 265/75/16 Cooper Disco STTs? Would an RTC Damper solve this?

I am aware you can adjust the box to give tighter steering but would like to solve the leak/issues before, also seems like a difficult job...

Any help would be fantastic.

Update -

Standing still - few drops over 12 hours.

Driving around and stopping for a few moments, at least 1- 2 drops every 5 seconds. Leaves a noticable puddle.

The steering symptoms sound to me like there is a loose ball joint somewhere. but it could be slack anywhere. You'll just have to work your way through all the components and see if any are allowing excessive movement. Mine felt like that when the retaining plate and cup dropped out of the bottom of my drop arm ball joint, but yours can't do that any more so it must be elsewhere.

The gearbox oil leak looks like it might be coming from between the transfer box and main box (R380 in your case perhaps?). In which case maybe one of the seals between the two boxes has deteriorated. Looks a bit too thin and runny to be EP90 - perhaps it's the MTF94 out of the main box. It looks like it's time to separate the two and see what's what. In the meantime keep checking the main box oil level!

t/box leak may well be intermediate shaft , it runs through both sides of case rear has a nut and front an oring but case wears allowing oil to leak out , if not too bad it can be fixed by undoing the nut pushing shaft forward enough to change oring clean hole and apply silicone on inner side of oring then push shaft back then retighten nut till free play is just removed from intermediate gear , pas box will be lower seal stc2848, can be done on vehicle if drop arms removed, circlips removed ,oil catcher put underneath and run engine and turn steering wheel till seal blows out ,clean shaft etc and fit new seal ,steel washer, circlip, mudseal, if shafts very pitted it might not be a permanent fix , for steering hold all the differnt rods etc whilst someone rocks steering wheel vigorously you should be able to feel were play is

Thanks guys very helpful.

I recently changed the gearbox oil and the oil coming out is rather clean so probably the seal. If this is the case i'll just keep an eye on it until I have garage space free.

Should be able to get the drop arm off with some relative ease since its been changed once quite recently....

The TX/GB leak appears to have slowed down to what it was before now. Im hoping theres still oil in there! Need to check that... Is it possible I overfilled the box when changing the oil?

Steering wise enourmous amounts of play. Bonnet up, engine off - Went to check the UJs all appear in order however massive play probably half a turn each side and the wheels dont move at all!

I was reading (cant find the link now..) that the play can be adjusted via a nut on top of the steering box. I shall give this ago on the weekend. Hopefully when I do this the steering will actually feel connected again. This leak also appears to have slowed, havnt had to top up in some time.

Dodgy steering was down to a loose bolt on the Panhard rod... Steering has zero play now so very happy.

I also have a transfer box leak. The oil is coming out of the rear output, along the bolt. It hasn't been driven yet since fitted and looks like my mate didn't tighten the 30mm nut.

Will tightening this nut, as James suggested, just to take up the play, solve the leak or do I need to replace the seal? The only annoying thing is, I'm sure the seal was placed when we replaced all the gaskets.

When I pull the drive out, the oil leak is worse, when I push it in (to where it would be if the 30mm nut was tight) there seems to be little to no leaking.

Cheers

Finally had a chance to get around to this today.

Gearbox has not lost a drop since I serviced it.

TX Box however has lost a lot! Around 500 - 600ml of thick black/grey goo came out, 2L went back in...

Need to get that fixed....