how to check transfer box i-shaft hole is worn out (oval)

I have 2004 disco. td5. How can I check its transfer box i-shaft hole has been oval from outside? I guess i-shaft is fixed with external lock nut, if it it is not loose, can I say it is not oval yet.

Not really! The problematic side is on the gearbox side and hard to see. If it is leaking oil in that area and even you change the O rings still leaks than it is worn and better to sleeve it (or change to the sleeved casing). I did it last year, together with major overhaul, since it is fine!

nut side doesnt wear,the other that does will have grooves if worn

Not seen a worn one yet on a D2, I think that's mainly down to the factory selectable shim rather than a crush spacer - those let the shaft jink about if not correctly fitted.

Main issue if it's leaking there will be the o-rings.

Bennehboy said:

Not seen a worn one yet on a D2, I think that's mainly down to the factory selectable shim rather than a crush spacer - those let the shaft jink about if not correctly fitted.

Main issue if it's leaking there will be the o-rings.

Click to expand...

have you not ,i find the wear probably more common,and whether its collapsible spacer or sized tube they both have play as bearings wear though you can easily take this up with the collapsible spacer you cant with sized tube

I guess I've just been lucky

I degreased the t-box today and drawed a line across i-shaft and the case. After 20 miles drive, it seems the i-shaft has no drift and is dry under it. Possibly the i-shaft hole is still in good condition, but I saw oil out from a small seam btw the g-box and the t-box. It is likely the input seal is leaking.