You can see it here. Lots of info on the web about it, Woulld be my first point of investigation to check it.



Cheers

Standby just took a photo and it’s quite interesting, I managed to get a light right in there, the cables near the gear levers are very wet
E318D7C1-5093-4B43-859D-04DA0624BB1B.jpeg
 
It appears very wet up near the top part near the levers and is suspect it’s dripping down from there.
 
This is the only oil I see and I’ve taken the plate out above the transfer box and removed the gear box gaiter and foam. I can’t see the oil from near the levers as shown in the photo has dropped down, therefore I’m guessing it is the intermediate shaft O ring as suggested due to the oil appearing at the lower end of the front of the transfer box, starting approximately halfway down the face of that box. No oil seen dripping down above this point. Thoughts welcome on that.
 
image.jpg
image.jpg
Ive definitely identified this as the intermediate shaft leak, despite the garage thinking differently, they thought it was the output seal and redid it but taking it home, the seal is bone dry but just below the intermediate is soaked.
If the garage continue messing me around I’ll do it myself.
Question:
Can I get this shaft out completely to renew both O rings without taking the transfer box out. My access should be fairly easy as it’s a military one and I can see almost everything. This is the access I have to the box and the shaft itself.
 
To do a proper job, the box needs removing. I have read that it can be slid back enough to poke the shaft out sufficiently to replace the o ring but I’d be inclined to just take the box out and do the job on a workbench.
I have to do mine soon as I fitted the disco transfer box in haste, without taking the time to do the seals first so now I need to take the box out again:(! I know, I’m an idiot!!:D
 
To do a proper job, the box needs removing. I have read that it can be slid back enough to poke the shaft out sufficiently to replace the o ring but I’d be inclined to just take the box out and do the job on a workbench.
I have to do mine soon as I fitted the disco transfer box in haste, without taking the time to do the seals first so now I need to take the box out again:(! I know, I’m an idiot!!:D
How you planning on getting it out, bit of muscle and a jack?
 
Working alone, I use this.....
D20DCB1D-A0B2-4C74-83E8-C2F65E3FB383.jpeg

It bolts to the inspection cover and provides a flat surface for the trolley jack to work on. Similar could be made from wood....
If I have a helper, it can be mauled around quite easily. It’s not particularly heavy but it is an awkward, unbalanced thing to lift into position single handed lay, with any control or finesse!!
 
As mentioned earlier I've also made the plate shown in callisr's pic. Drilled the base for a big bolt that fits my trolley jack after taking its saddle off.
Not sure I'd trust a wooden one.
For the guide studs I cut the heads off long bolts - my see earlier post. I tried threaded studding. It isn't strong enough, bends too easily & unlike the bolt which can be nipped up tends to wobble about.
 
The garage eventually (after a lot of arguing) replaced my intermediate shaft seals. No more leaks at all, the Defender is now leak free.
Thanks for all your input, I wasn’t afraid of doing it myself after all your information.
Thanks
 
The garage eventually (after a lot of arguing) replaced my intermediate shaft seals. No more leaks at all, the Defender is now leak free.
Thanks for all your input, I wasn’t afraid of doing it myself after all your information.
Thanks

Probably empty.......
 

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