I'm thinking the motor thinks it's in high but the box is in low. So if I switch the motor to low whilst off the box I can refit and the two will both be singing each other's sweet songs?

You can take the motor off, turn the triangular shaft thingy to shift it to high / low and then just refit the motor.
 
So, today I have refit my transfer case (so much fun for a guy to have with a trolley jack on gravel). It's wonderful to have a day above zero degrees to work in!
And... it works. I've fixed a thing.

Next up is to change the gearbox fluid and filter and refill the transfer box. Fit new transmission brake shoes and the props and I'm done.
 
Right. Now we're all back together and working. Swapped the atf in the tranny whilst it was on stands. But, on refilling the transfer box I have oil leaking into the transmission brake drum... f*** I put a new seal on the rear too.
 
Right. Now we're all back together and working. Swapped the atf in the tranny whilst it was on stands. But, on refilling the transfer box I have oil leaking into the transmission brake drum... f*** I put a new seal on the rear too.
Not lucky are you?
 
Right. Now we're all back together and working. Swapped the atf in the tranny whilst it was on stands. But, on refilling the transfer box I have oil leaking into the transmission brake drum... f*** I put a new seal on the rear too.

The seal has to be the same distance out as the previous one. Gentle tapping it in. Worth getting some very fine grit Wet and Dry and some oil as lubricant and then polishing the flange where the seal sits before reassembly. Any roughness on that flange will chew up the new seal. I wouldn't use Britpart or Bearmach for that seal myself.

If it is a really high roller the metal can be eaten where the seal touches. It might be possible to fit a metal sleeve over the top.
 

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