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Yannis



Member Since: 02 Feb 2015
Location: Oxfordshire / Milan
Posts: 408

United Kingdom 2015 Defender 90 Puma 2.2 CSW Corris Grey
Oil Leak
I have an oil leak that is now big enough to be making a mess of the driveway.

It’s coming from 1 of 3 places…

Gearbox output seal
Transfer box input seal
Intermediate shaft o-ring

I made the “drain” hole in the extension casing bigger so I could get a borescope into have a look, but it’s difficult to tell which end is leaking.

2 questions;

Part numbers of the seals; (correct?)
Gearbox output seal - LR0058800
Transfer box input seal - ICV100000
Intermediate shaft o-ring - FRC8292

Can the nut on the front of the intermediate shaft be undone and the shaft pushed backwards just enough to replace the o-ring?

Cheers

Yan
Post #997340 24th Jun 2023 7:19am
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blackwolf



Member Since: 03 Nov 2009
Location: South West England
Posts: 17443

United Kingdom 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey
Yannis wrote:
... Can the nut on the front of the intermediate shaft be undone and the shaft pushed backwards just enough to replace the o-ring?


Not with the transfer box bolted up to the gearbox. It is in theory possible to slide the t-box back from the gearbox on guide studs but by the time it's disconnected from everything to allow this you might as well remove it and work in comfort and in cleanliness.

The t-box and gearbox oils are distinctively different so it should be possible to tell which one is the source of the leak.
Post #997349 24th Jun 2023 9:10am
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Yannis



Member Since: 02 Feb 2015
Location: Oxfordshire / Milan
Posts: 408

United Kingdom 2015 Defender 90 Puma 2.2 CSW Corris Grey
I planned to drop the box as its an easy enough job. Can do all 3 seals in one go then.

Just wondered if carefully pushing back the intermediate shaft to replace the o-ring was possible?
Post #997353 24th Jun 2023 9:30am
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blackwolf



Member Since: 03 Nov 2009
Location: South West England
Posts: 17443

United Kingdom 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey
Yes, but remember that you'll need to set the preload afterwards, and that, depending on mileage and the amount of wear in the IS bearings, is likely to require a new spacer or crush tube.
Post #997355 24th Jun 2023 9:40am
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Yannis



Member Since: 02 Feb 2015
Location: Oxfordshire / Milan
Posts: 408

United Kingdom 2015 Defender 90 Puma 2.2 CSW Corris Grey
Cleaning up the end of the shaft and making a silicone seal is probably the better option then….
Post #997358 24th Jun 2023 10:06am
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blackwolf



Member Since: 03 Nov 2009
Location: South West England
Posts: 17443

United Kingdom 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey
I'm not sure I agree with "better", although it may be simpler! Very Happy

Doing it properly isn't difficult, but it takes a little longer and needs a couple of extra tools.
Post #997368 24th Jun 2023 11:14am
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Yannis



Member Since: 02 Feb 2015
Location: Oxfordshire / Milan
Posts: 408

United Kingdom 2015 Defender 90 Puma 2.2 CSW Corris Grey
My worry is that the intermediate shaft is leaking because it’s hole is now slightly oval…
Post #997377 24th Jun 2023 2:02pm
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blackwolf



Member Since: 03 Nov 2009
Location: South West England
Posts: 17443

United Kingdom 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey
Quite possible, I'm afraid, but if so there is no satisfactory enduring repair other than getting the case machined and collared.
Post #997379 24th Jun 2023 2:25pm
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Yannis



Member Since: 02 Feb 2015
Location: Oxfordshire / Milan
Posts: 408

United Kingdom 2015 Defender 90 Puma 2.2 CSW Corris Grey
I live in Italy and since Brexit, customs are absolutely screwing us with charges for anything arriving from the U.K. Big Cry

I think a trip to the U.K. next year and a transfer box swap in the carpark of Winchester Gears is in order……
Post #997385 24th Jun 2023 3:50pm
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Race.it



Member Since: 27 Aug 2019
Location: Algeciras
Posts: 823

Spain 2010 Defender 110 Puma 2.4 SW Alaska White
I may see you in the carpark (from Spain) had the same idea due to the lovely charges that are randomly generated but always applied. Searching for my first Defender...and started just as Covid hit, so talk about timing.

5 months after starting the search I found it, and here is the details
Post #997441 25th Jun 2023 8:30am
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