 | Home > Technical > Gearbox output shaft leak |
 
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| SimonDavies Member Since: 15 Mar 2012 Location: Swansea Posts: 244   
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I'm hoping someone has some experience of a leak I have acquired.
My transfer box intermediate shaft went kaput a few months back. A local indie carried out the repair. He renewed the shaft (as a kit I believe?) and I had the 90 back and all was ok until I noticed a puddle. It went back to the indie who said in hindsight he should have replaced the seals on the gearbox and transfer box side. Out came the transfer box and he changed both seals. My landy still leaked. I checked which oil had leaked and found the gearbox oil to be low. I reported to the indie, who put another seal in (so I'm told). The correct amount of oil was put back in (2.2l I believe). But yep, you guessed it, I still have a leak. To look underneath, the leak comes from the little cut out between gear and transfer boxes. The indie says there is no play anywhere and he is 100% confident of the way he puts the seal in. He does have 30 years plus experience. He has mentioned having to weld a tool to the intermediate shaft to remove. I'm wondering if this has anything to do with the leak. I appreciated any comments, I'm hoping someone has an idea. |
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12th May 2016 9:07pm |
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| custom90 Member Since: 21 Jan 2010 Location: South West, England. Posts: 20612 
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Is the area in question a 'V' shape and nearest the ground?
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12th May 2016 9:09pm |
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| SimonDavies Member Since: 15 Mar 2012 Location: Swansea Posts: 244
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The cutout? Yes, on the underneath between the boxes. Maybe more of a 'd' from memory.
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12th May 2016 9:13pm |
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| blackwolf Member Since: 03 Nov 2009 Location: South West England Posts: 17600 
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Out of interest, how did you determine that the gearbox oil level was low?
This thread - http://www.defender2.net/forum/topic46148.html ... has photos of the location of the drain hole in the intermediate shaft housing; I imagine this is the location of your discharge? Last edited by blackwolf on 12th May 2016 9:22pm. Edited 1 time in total |
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12th May 2016 9:17pm |
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| nitram17 Member Since: 08 Jun 2014 Location: newcastle Posts: 2261 |
by cut out do you mean an indentation about an inch wide?it may be a warped ladder rail!
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12th May 2016 9:18pm |
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| SimonDavies Member Since: 15 Mar 2012 Location: Swansea Posts: 244
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Black wolf: that is the cutout I'm referring to.
At first I was having a red oil making a puddle. I checked the transfer which was, yellow (oil colour) and then checked the gearbox which had a red colour. I have done approx 3000 miles since my indie put the 2.2 litres in the box. This evening I drained the box into a clean bucket and measured it at 1 litre, give or take. Nitram: warped 'ladder rail'. Caused by the weld? |
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12th May 2016 9:32pm |
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| SimonDavies Member Since: 15 Mar 2012 Location: Swansea Posts: 244
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 . Surely it could only be the welding in that area to warp the housing? I didn't have any leak before my shaft went.
Thanks for your responses by the way, guys |
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12th May 2016 10:18pm |
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| blackwolf Member Since: 03 Nov 2009 Location: South West England Posts: 17600
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I am a bit puzzled by this talk of the "ladder rail".
The ladder rail or stiffener as I understand it is a component fitted to the bottom of the crankcase (between the block and sump) to provide stiffness to the bottom of the crankcase. I don't see how it can possibly have been affected by, or be causing, a leak form the back of the gearbox! It is also not really clear what the indie meant with the talk of welding something. My guess would be that they are saying that they don't have the correct tool for locking the part of the adaptor shaft coupling that is bolted on the gearbox, and therefore welded a bar or spigot on it to hold it. If they did this taking the old one off, it probably won't do much harm even though it is shoddy engineering. If they did this to the new one to tighten up the retaining nut, then it is quite possible that some damage may have been done. A further point is that if they later replaced both the gearbox output shaft seal and transfer box seal, they would have had to take the new coupling off the gearbox to fit the seal. Did they do the welding thing to get the new coupling off? From what you have said, I have my doubts as to whether they have actually changed the the gearbox output shaft seal at all. Since the sealing surface upon which the seal runs is on the gearbox part of the coupling that has been replaced, it is possible that either the old seal simply isn't sealing adequately on the new coupling, or the old seal was damaged by heat and has become useless. Either way I think you'll have to have the transfer box off again to investigate, and I have to say that I'd be inclined to get someone else, not your indie, to do it. Incidentally if the gearbox has lost more than half its oil in that distance, it is a massive leak and really needs sorting before you use the vehicle in order to prevent gearbox damage. |
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13th May 2016 8:25am |
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| SimonDavies Member Since: 15 Mar 2012 Location: Swansea Posts: 244
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I had no idea what the 'ladder rail' was in all honesty. Now that you have explained the location Blackwolf, I do agree that I don't think this is the cause of my leak.
He didn't mention having to remove the coupling again to change the seal but it sounds like it would be worth asking him. I'm pretty competent myself on the spanners, so I'll be pulling it out myself next. When the splines went I simply didn't have the time to do the work myself. |
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13th May 2016 12:38pm |
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| Caterham Member Since: 06 Nov 2008 Location: Birmingham Posts: 6318  
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Simon,
not wanting to be alarmist but when my extension went first time round I had a similar problem.....the seals where changed more than once by the LR dealers ....I think they thought I was doing something malicious. anyhow they got LR rep in to oversee the seal change. I got a phone call to confirm all was ok. Then another call once they'd completed another test drive to confirm I needed a new gearbox because the original had become 'porous' ! ? ! ? new gearbox no leaks? |
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13th May 2016 1:10pm |
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| nitram17 Member Since: 08 Jun 2014 Location: newcastle Posts: 2261 |
I will have to admit i jumped to conclusions i saw the half moon cut out and i knew i had a leak from there but i didnt realise there was a another cut out further back sorry folks i will read the full post next time! |
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13th May 2016 6:35pm |
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