TransferBox Broken

Hi.

I have 1993 200TDI Defender 90. All was well un til today when the transfer box started leaking oil everywhere and making a noise (not a sharp metallic noise). If you follow the front prop into the box there is a metal circular thing that looks like it fits into the end of the transfer box. This has come out and i am sure its where the oil is coming from.

Anyone any ideas why it happened and what damage I may have done? I had the landy taked home on the back of a lorry to avoid any further damage.

Andy

The "circular thing" is the transfer box output flange. You will firstly need to work out how\why this came off.

To replace the flange and oil seal, drain the transfer box of oil (via the drain plug). Remove the prop-shaft. Remove the output flange. Inspect the flange for damage and replace if need be. Replace oil seal. Inspect the seal locating bore on the transfer box for sharp edges (these would rip a new seal otherwise). Fit new oil seal. Refit output flange. Refit propshaft.

If you get some pictures, I could take a look at the damage.

Hiya. Thanks for the info, I had a closer look to suss out why the flange came loose and I think its because the Uinveral Joint at the end of the front prop before it goes in to the transfer box had worn and was shaking. There was a large amount of movement in it and i think this shook the flange out especially since the vehicle has done a huge amount of motorway miles with some fairly savage offroading in between. So this evening its getting a new uinveral joint, flange and oil seal and it should be back on the road!!!


andy

Sounds good. I check my UJs once a week for movement, and pump more grease into them at the same time. It only takes a few minutes, and ensures they stay in good nick.

Well I got a new UJ and oil seal put on last week whilst i was away. Then i took the 90 up to the lake district on Thursday for the weekend. It broke down after 340 miles, the UJ exploded and damaged the front prop aswell. It seems unlikley to have two dodgy UJs in the space of 400 miles so I can only assume that the transfer box is seizing up and winding up. When it releases its produces to much torque for the joint and that explodes. So the car spent another journey on the back of an AA lorry and is now outside MJ Fews dealership waiting to be looked at tomorrow!!

Andy

You've gone from describing what you didnt know as a transfer box output flange as a "circular thing" to making reference and offering an opinion on excessive torque forces resulting in exploding UJs from the effect of winding transfer boxs...you've been talking to someone havent you...!

mate this thread is coming up for 4 years old... if he aint worked out his flanges yet hes well ****ed!