 | Home > Technical > LT230 Intermediate Shaft Seal Leak Fix |
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| roel Member Since: 08 Aug 2009 Location: Lelystad Posts: 2039   
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I am not sure if that works or not , so I cannot comment on that.
My steering box is sweating a little too so how much brake fluid did you add? I assume that your transfer box is leaking btween the gearbox and the transfer box where the end of the intermediate shaft is. Prbably just changing the O-ring will only be a temporary fix as the hole were the shaft sits is is worn out. So you probably need a new housing. I had the same problem, changed the O-ring and the leak was back in some months so I tried something different. First I cleaned it very good without seperating the gearbox and tranferbox just worked from below the 90. I made this:  Click image to enlarge I glued this with plenty off blue silicon in the area over the end off the intermediate shaft. I did this in November 2017 and still no leaks. Roel 1984 90 2.5 na Diesel - RR V8 (1994-2001) 1997 Camel Trophy Discovery 300TDI (2001-2009) 2005 G4 Discovery III 4.4 V8 (2008-2018) It's gone but it still hurts. 2003 90 Td5 (2009-now) |
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7th Jun 2018 9:19pm |
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| Freddie Member Since: 21 May 2014 Location: Cape Town Posts: 46  
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Ha! I always get a kick out of seeing the lengths we land rover guys go to fix a leak.
By the sounds (and looks of it) we are talking about the same thing. If the hole is worn out - perhaps that's a good enough excuse to get my hands on a DURAspec LT230 from Syncro gearboxes... 
In the meantime, I'll whip up something similar and let you know if it works - thanks Roel! Re brake fluid for power steering leak, if I remember correctly it was two caps full. The caps were small, so probably the same as two tablespoons. |
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8th Jun 2018 7:22am |
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| roel Member Since: 08 Aug 2009 Location: Lelystad Posts: 2039
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Thanks,
I will try that too.  Roel
1984 90 2.5 na Diesel - RR V8 (1994-2001) 1997 Camel Trophy Discovery 300TDI (2001-2009) 2005 G4 Discovery III 4.4 V8 (2008-2018) It's gone but it still hurts. 2003 90 Td5 (2009-now) |
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9th Jun 2018 9:46pm |
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| Freddie Member Since: 21 May 2014 Location: Cape Town Posts: 46
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It aint pretty but its installed - with LOTS of silicone. Will keep you posted..
Click image to enlarge Click image to enlarge |
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11th Jun 2018 4:19pm |
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| roel Member Since: 08 Aug 2009 Location: Lelystad Posts: 2039
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That is not lots of silicon.
 Or was that a trial fit picture? Roel
1984 90 2.5 na Diesel - RR V8 (1994-2001) 1997 Camel Trophy Discovery 300TDI (2001-2009) 2005 G4 Discovery III 4.4 V8 (2008-2018) It's gone but it still hurts. 2003 90 Td5 (2009-now) |
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11th Jun 2018 10:33pm |
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| MadTom Member Since: 10 Sep 2013 Location: Olomouc Posts: 622  
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I made it the "Ashcroft way" - dismantle the gearbox, make the oval hole bigger and press in a steel sleeve. Now after two years it is OK. It was a small job with lathe and mill. Most of time I spent thinking, how to do it and how to align everything. "Drobek" = The Small One - Discovery 2, "Blufínek" = The Blue Thing - Defender 130, and for me at least Ford Mondeo
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12th Jun 2018 6:12am |
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| Freddie Member Since: 21 May 2014 Location: Cape Town Posts: 46
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Trial fit.. You can't see the plate anymore |
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12th Jun 2018 8:19am |
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| Bushpig Member Since: 07 Nov 2013 Location: Risca, Wales Posts: 236  
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Hi Freddie
Is the fix still working? Mine has just started leaking again after fitting new seal around 3 months ago  Human beings, who are almost unique in having the ability to learn from the experience of others, are also remarkable for their apparent disinclination to do so.
Douglas Adams 2012 2.2 Puma |
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16th Jul 2018 11:10am |
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| Freddie Member Since: 21 May 2014 Location: Cape Town Posts: 46
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Hi, Sorry for the delay in getting back to you.
Frustratingly I had run out of the normal Silicone that I use (Victor Reinz - great stuff!) and ended up using Loctite Grey, which ended up peeling off when I steam cleaned the undercarriage 
Before that, it did seem to stop the leak and I'd bet when I redo it with the Victor Reinz it'd be a more than temporary 'temp fix'.. Give it a whirl! |
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25th Jul 2018 8:50am |
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| Bushpig Member Since: 07 Nov 2013 Location: Risca, Wales Posts: 236
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No worries on the delay, I'm only back with my vehicle at the end of the week.
When you have the piece off, would it be possible to take some better measurements or perhaps a picture on a piece of graph paper? I'll only have a day before heading off up the west coast, hoping to make Eksteenfontein and would rather do the fix before going. I know it is being a bit lazy, but I must also do a full service (100 000km), all fluids, brakes, seal the wing ducting to the blower, etc & shopping. So any time saving would be a great help. Did a quick Google and there are suppliers in Strand who stock the Reinz stuff, but only the Renzosil. Is this what you use or is it the Renzoplast? Apologies for all the questions and requests... Much appreciated  Jason Human beings, who are almost unique in having the ability to learn from the experience of others, are also remarkable for their apparent disinclination to do so.
Douglas Adams 2012 2.2 Puma |
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25th Jul 2018 11:56am |
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| Freddie Member Since: 21 May 2014 Location: Cape Town Posts: 46
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Hey Jason, No problem, I'll see what I can do!
I use the Reinzosil. In SA and Tonnesen / Midas Auto Spares store will stock the stuff. |
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31st Jul 2018 10:35am |
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| Freddie Member Since: 21 May 2014 Location: Cape Town Posts: 46
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Hi Jason,
You inspired me to fix the thing.. I revised the design slightly to allow for the curve of the gearbox. It's also a little better fit so hopefully, it will create a better seal. Here is a picture of the new design (right): Click image to enlarge And a copy of it on graph paper. Click image to enlarge I didn't have any, so I printed this one. Typically the blocks ended up being 12 x 12mm. https://store.schoolspecialty.com/OA_HTML/...tion=Large Hope that you can recreate it! Will check back as to how well it works. |
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31st Jul 2018 1:45pm |
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| Freddie Member Since: 21 May 2014 Location: Cape Town Posts: 46
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This is certainly the way to do it. Something for when I can be bothered to pull everything apart  |
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31st Jul 2018 1:47pm |
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| MadTom Member Since: 10 Sep 2013 Location: Olomouc Posts: 622
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It took 4 years to really start the work. Transfer box was fully covered in mud, sand and oil mixture at that time. The last point to start the work was clutch spigot bush - it started making bad noise and slowly during 4 year going to be worse, up to the state, that it was hard to shift between gears, and in low gear the car was moving with depressed clutch pedal. So spigot bush replacement - 3 GBP thing, and I made clutch and both gearboxes, because they has to be removed, to replace the bush. Small things can be a bit expensive to repair. "Drobek" = The Small One - Discovery 2, "Blufínek" = The Blue Thing - Defender 130, and for me at least Ford Mondeo
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1st Aug 2018 6:47am |
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