Disco 2 Transfer box leaks again

Hi All

Since I have my D2 I have had slight leak from intermediate shaft. First a local mechanic changed it, was good for about a month. After, due to other things I wanted to do (main shaft seal, gearbox seals), I have removed the box and changed O rings and seals. It was good for more than 7 months, but it has started to leak again.
I plan to remove it again (I hate oil leak) and will try to fix. I am thinking to sleeve the casing by using steel bush from Ashcroft.
Anyone with any experience with such repair? While the box is off should I change other things in it?
Maybe a stupid question: the box did not have any leak for several months but about a month ago I have used the low gears a few times (not hard offroading just tried it on country roads) and the leak started after.
Can it be that the intermediate shaft got a different force while using low gears which made the fit between the shaft and the housing bad which coused oil leak?

Hi, i can't tell you why it's leaking but if you want the best for yourself get a master rebuild kit too but if you dont want to invest that much buy at least the diff thrust washers cos i'm sure they are worn, when mine was rebuilt two of them were completely ''chewed" and the others very thin, nr 4 http://new.lrcat.com/#!/1232/39784/39785/3055/39795 ... i fitted a HD cross pin in mine as well

berg450 said:

Hi All

Since I have my D2 I have had slight leak from intermediate shaft. First a local mechanic changed it, was good for about a month. After, due to other things I wanted to do (main shaft seal, gearbox seals), I have removed the box and changed O rings and seals. It was good for more than 7 months, but it has started to leak again.
I plan to remove it again (I hate oil leak) and will try to fix. I am thinking to sleeve the casing by using steel bush from Ashcroft.
Anyone with any experience with such repair? While the box is off should I change other things in it?
Maybe a stupid question: the box did not have any leak for several months but about a month ago I have used the low gears a few times (not hard offroading just tried it on country roads) and the leak started after.
Can it be that the intermediate shaft got a different force while using low gears which made the fit between the shaft and the housing bad which coused oil leak?

Click to expand...

i dont know about ashcrofts first hand but id think they are done properly, sleeving the hole is something we were doing in the 90s and its a very good fix but it has to be done taking its center from the hole on the other side of case so not a diy job

sierrafery said:

Hi, i can't tell you why it's leaking but if you want the best for yourself get a master rebuild kit too but if you dont want to invest that much buy at least the diff thrust washers cos i'm sure they are worn, when mine was rebuilt two of them were completely ''chewed" and the others very thin, nr 4 http://new.lrcat.com/#!/1232/39784/39785/3055/39795 ... i fitted a HD cross pin in mine as well

Click to expand...

Have you done the rebuild by yourself? Can it be done without expensive special tools?
I am also thinking to buy rebuild kit, it is not that expensive and if i remove the box again I want to make it right.

jamesmartin said:

i dont know about ashcrofts first hand but id think they are done properly, sleeving the hole is something we were doing in the 90s and its a very good fix but it has to be done taking its center from the hole on the other side of case so not a diy job

Click to expand...

No I do not want to do it by myself I want to make it done by a machine shop specialized for engine parts. Or do you think better to buy a sleeved casing from Ashcroft? They offer it as well.

berg450 said:

No I do not want to do it by myself I want to make it done by a machine shop specialized for engine parts. Or do you think better to buy a sleeved casing from Ashcroft? They offer it as well.

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probably ashcrofts as alignment is critical

jamesmartin said:

probably ashcrofts as alignment is critical

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Thanks. I will discuss with them how to proceed.

berg450 said:

Have you done the rebuild by yourself? Can it be done without expensive special tools?
I am also thinking to buy rebuild kit, it is not that expensive and if i remove the box again I want to make it right.

Click to expand...

No, i'm not so handy with mechanics but i asked my mechanic and he said it wasnt so bad and he doesnt have any special LR tool just general auto mechanic tools ... though he is well ''equipped'' with everything needed in a serious auto service

jamesmartin said:

probably ashcrofts as alignment is critical

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I have talked to a retired land rover machanic (and ex service owner) and asked if he knows a reliable local shop to do the box renewal. He said yes but they used to do it on a different way, by making the hole bigger and also making bigger shaft which fits to it, but no bush. Today I have asked for an offer and the work plus renewal would cost about 250 pounds (without removal and installation).

berg450 said:

I have talked to a retired land rover machanic (and ex service owner) and asked if he knows a reliable local shop to do the box renewal. He said yes but they used to do it on a different way, by making the hole bigger and also making bigger shaft which fits to it, but no bush. Today I have asked for an offer and the work plus renewal would cost about 250 pounds (without removal and installation).

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apart from thats quite a cost,i dont really think thats a good solution,the point is that hole wears oval and so to get correct center you need to take that from the hole on the other side which will still be true,id expect to pay 100 ish at my local engineering place that do the bush fit

jamesmartin said:

apart from thats quite a cost,i dont really think thats a good solution,the point is that hole wears oval and so to get correct center you need to take that from the hole on the other side which will still be true,id expect to pay 100 ish at my local engineering place that do the bush fit

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You are right. But I guess they have already done several and they know how to take the correct center (they need my complete box) and for the 250 pounds they will do bearing change, thrust washers, seals, set up.
A worry a bit to order a half case (sleeved) from Ashcroft as in case of any issue to send it back would make it very expensive for me.

berg450 said:

You are right. But I guess they have already done several and they know how to take the correct center (they need my complete box) and for the 250 pounds they will do bearing change, thrust washers, seals, set up.
A worry a bit to order a half case (sleeved) from Ashcroft as in case of any issue to send it back would make it very expensive for me.

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if they do bearings etc for that price then fair enough

jamesmartin said:

if they do bearings etc for that price then fair enough

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I have tried to get some more info regarding on the content of the renewal, no feedback yet. So maybe i will order the ashcroft case with rebuild kit and do by myself. Will the sleeved casing what ashcroft sends be in centre with my case? Do not they need the other half when they do the machining?
My box has a selective spacer, can i use collapsable one or i will need to order the right size when i assamble it?

berg450 said:

I have tried to get some more info regarding on the content of the renewal, no feedback yet. So maybe i will order the ashcroft case with rebuild kit and do by myself. Will the sleeved casing what ashcroft sends be in centre with my case? Do not they need the other half when they do the machining?
My box has a selective spacer, can i use collapsable one or i will need to order the right size when i assamble it?

Click to expand...

you can use the collapsible spacer,
ashcroft case should be correct and you only need the main housing

Thanks. I will order the case and the rebuild kit and let you know how i proceed.

jamesmartin said:

you can use the collapsible spacer,
ashcroft case should be correct and you only need the main housing

Click to expand...

I have not ordered the parts yet and want to do it only after removing the box and opening it up to see what else i would need to rebuild it. Checked yesterday the play of the output flanges and found around 8-10mm. See 2 marks on the photo. Is it normal or it comes from the normal wear of the parts?

jamesmartin said:

you can use the collapsible spacer,
ashcroft case should be correct and you only need the main housing

Click to expand...

I have completed the rebiuld by using new sleeved casing from Ashcroft and all new bearings, shims which are included in the rebuild kit. So far looks good...
But I have a small issue....while I installed the intermediate shaft and the small O ring has slightly demaged by the sharp edge of the shat. I do not want to reuse it so I want to order new one locally. I have ordered some from the local LR dealer, but also want to find a better grade if there is. I have red somewhere that Viton is better. Is that right or standard will do the job as well? Is the correct size 25,07x2,62?