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Mining Subsidence Stu

Member Since: 06 Mar 2024
Location: Cornwall
Posts: 36

1991 Defender 90 200 Tdi HT Caledonian Blue

Transfer box throwing oil out.

Transfer box (with roamerdrive) has been getting more noisy. I filled with oil and now a lot of it is on the back/underside of the car. Obviously, RD is expensive and I don't want to

it.

Anyone got any ideas what is likely to have blown and how much of a pain it is to sort?

I think it's the front (gearbox side) of the box, possibly higher up.

Bloody thing. This one was £20k and had a £30k (cost) restoration in 2016. It has just gone wrong over and over and over again. My 300 was fine, but rusted.

14th Apr 2025 11:29am

TexasRover

Member Since: 24 Nov 2022
Location: Paris
Posts: 1230

2002 Defender 110 Td5 DCPU Chawton White

I believe there is an issue with the intermediate shaft mounting hole at the front side (front of vehicle) wearing out to the point that the shaft is loose and leaking oil.

It must have something to do with the amount of load the transfer case is seeing because I opened two up and both were fine it that area. I know Ashcroft do an improvement where I think they insert a bush (sleeved casing) https://ashcroft-transmissions.co.uk/produ...ed-casing/

I would look there first. On a Series transfercase excessive gear noise is normally associated with the intermediate gear bearings wearing, which by logic could be the same in an LT230 if that intermediate shaft is misalighned.

I have a roamerdrive on mine and there is no gear noise at all in drive with only the faintest whine in overrun.. Worth having I believe.

14th Apr 2025 12:44pm

Retroanaconda

Member Since: 04 Jan 2012
Location: Scotland
Posts: 2725

There are numerous places the LT230 can leak, but the front/rear output shafts and intermediate shaft are favourites.

14th Apr 2025 5:53pm

Mining Subsidence Stu

Member Since: 06 Mar 2024
Location: Cornwall
Posts: 36

I've got a full set of seals/gaskets and I'm going to have a go!

14th Apr 2025 9:07pm

Oldowner

Member Since: 26 Dec 2018
Location: South west
Posts: 648

2007 Defender 90 Puma 2.4 HT Aintree Green

Pull it apart and check the intermediate shaft hole in the casing. I have at a guess had forty plus LT230’s apart, they all have had wear to the casing, some much more than others. On the last few I rebuilt I’ve had Ashcroft sleeve the casings which I’ve sent up to them.

You will also have to change the shims in the diff as they will be worn, it’s worth putting a HD cross pin in there, and also purchase a HD intermediate shaft to go with the new bushing.

Pm me if you want to borrow all the special tools as you are fairly local, I’ve got an LT230 to reassemble in the next two weeks, after that I won’t need them for a while.

15th Apr 2025 3:21am

Mining Subsidence Stu

Member Since: 06 Mar 2024
Location: Cornwall
Posts: 36

I'm just having a big cup of coffee and a relax and then I'm going to take it out. Today's job is to get it out, get it looked at and get the seals/gaskets changed.

Reassembly may be later or tomorrow. I'm going to pace myself and take it steady.

Rushing is where it gets expensive.

My westfield blew a head gasket and Mr 4AGE engines had it back and had a look at it. Cue £5000 rebuild.

I do not want to be throwing money around on this bloody thing

16th Apr 2025 10:53am

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