1988 LR 90 Transfer Case Leak - Defender Source
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  #1  
Old February 10th, 2016, 10:08 PM
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Tom Schuler
1988 Defender 90
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1988 LR 90 Transfer Case Leak

Just got this 90 about a month a go and got busy changing fluids. Did axles and transfer case this weekend. Transfer case was down and now with fresh oil it seems to be leaking between where transfer case attaches to transmission. Anybody got any experience in this area? 🔧🔩⚙
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  #2  
Old February 10th, 2016, 10:28 PM
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John B.
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Yes. They leak from the intermediate shaft. It has an o-ring. Sometimes the casing can get distorted around the shaft as well.
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Old February 11th, 2016, 10:56 AM
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stephen gross
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LT230 Transfer Case leak

I have owned Land Rover vehicles with the LT230 transfer case since 1987. They all will leak at some point. The only solution is removal from the vehicle, complete disassembly, reseal and reassemble and install. My Defender has been leak free for 7 yrs. now. It takes a full day to remove, clean, reseal and reinstall the T-Case.

Expect to pay around $900.00 labor plus around $50.00 for the o-rings and gaskets. I use Permatex Right Stuff sealant for assembly. Make sure everything is very clean before reassembly- I use a parts washer.
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Old February 11th, 2016, 11:02 AM
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Chris
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$900 buys lots of 90wt
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A friend of mine runs a land rover / range rover specialty repair shop. Based on his experience, they are capable of stopping anywhere, anytime, at any cost.

I don't know about the brakes, only their unreliability.
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  #5  
Old February 11th, 2016, 11:10 AM
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Tom Schuler
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Thanks. Appreciate knowing what I have in front of me in terms of task. I will order a full set of seals, O-rings and Gaskets and set a weekend aside to do it...
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Old February 11th, 2016, 11:16 AM
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Tim
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If you have the time, post up some pictures when you do the repair. Thx
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  #7  
Old February 11th, 2016, 06:26 PM
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Tom Schuler
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Well, for starters here is a good photo summary of removing the transfer case...can't see me producing anything better than this for the removal/reinstall so this will be what I follow as step 1...Replacing an LT230 Transfer box - Land Rover Technical Archive - LR4x4 - The Land Rover Forum
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Old February 11th, 2016, 07:30 PM
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Tim
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Point taken. Yowza, that was a pretty all encompassing tutorial. Thx for posting the link.
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  #9  
Old February 12th, 2016, 09:15 AM
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Tom Schuler
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Bearmach has a great video about pulling the transfer case apart completely and reassembling. Reviewed it last night and based on the play I feel in the drive train when I shift I'm pretty sure Splines are shot on either the transmission output shaft or transfer case input gear (or both...). Input gear and bearings is a pretty simple job once the transfer case it out, so I'll do that as well...hopefully the splines on the main shaft out of the transmission are not too bad...
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  #10  
Old February 12th, 2016, 10:04 AM
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stephen gross
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If the splines on the main shaft are worn it will require a new main shaft. Big job and expensive.
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  #11  
Old February 12th, 2016, 06:11 PM
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Tom Schuler
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Yep. Hopefully the transfer case input gear is softer steel so those splines take most of the wear...We'll see. In the meantime I'll have the parts to replace the seals, input gear, bearings and races. Transfer case has 186k miles on it, so I guess some wear should be anticipated....couple of good videos on LT230 Transfer Box...one on pulling apart and putting it together..https://youtu.be/zZ8H17B5lyE and another on quick inspection of transmission output shaft splines while still installed in vehicle https://youtu.be/7vFPc5ZSRKg
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