LT230 Oil leak investigation

Hello fellow members

Today I removed my TC because It started to leak oil dramatically.

I’m pretty sure it is the well known intermediate shaft is leaking.


After removing the T case it looked like this: (1st 4 images)


The rear of the gearbox(R380) looks like this: 5th to 8th picture

Can it be that the IS leak goes inbetween the mating surfaces of the gearbox & transferbox?

The output shaft seal on the gearbox looks fine, the same goes for the input shaft seal of the TC. (going to replace them anyway)

I also noticed that the linkage arms of the gearbox are wet & it seems that oil is coming down from above..

Any idea what the cause/ failure of this could be?
(9th and 10th picture)

Blocked breather causing leaks anywhere oil can find a way out ?

tottot said:

Blocked breather causing leaks anywhere oil can find a way out ?

Click to expand...

Will try to blow the breather out, where is the end of the TC breather located?

Td5_vdv said:

Will try to blow the breather out, where is the end of the TC breather located?

Click to expand...

I think it's in the engine bay, back of the cylinder head on the bulkhead

Might be worth checking the banjo bolt where breather pipe fits on box

tottot said:

Might be worth checking the banjo bolt where breather pipe fits on box

Click to expand...

This +1. Normally worth buying a new breather banjo + new breather pipe as they're pennies to buy. Can recommend converting to a Gwyn Lewis breather kit as they don't rust solid like the std units

https://gwynlewis4x4.co.uk/product/defender-discovery-1-rrc-discovery-2-td5-puma-v8/

https://gwynlewis4x4.co.uk/product-category/wading-kits-fittings/

tottot said:

Might be worth checking the banjo bolt where breather pipe fits on box

Click to expand...

Thank you! Indeed they are located over there

v8250 said:

This +1. Normally worth buying a new breather banjo + new breather pipe as they're pennies to buy. Can recommend converting to a Gwyn Lewis breather kit as they don't rust solid like the std units

https://gwynlewis4x4.co.uk/product/defender-discovery-1-rrc-discovery-2-td5-puma-v8/

https://gwynlewis4x4.co.uk/product-category/wading-kits-fittings/

Click to expand...

Looks like a much better solution!

I have some pneumatic push-in connectors & tubes laying around, maybe I can try to make my own breather circuit.