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cykoh85



Member Since: 25 Apr 2022
Location: Selangor
Posts: 159

Malaysia 1990 Defender 110 200 Tdi SW Santorini Black
200TDI handbrake drum oil seal leaking
Hi all,

Does anyone know about any clip/circlip staked nut on the rear output shaft (30mm nut, as shown in the attached photo with the red circle)?

I tried to remove it yesterday but it was very difficult, so I gave up and just refilled with new oil.

My next question is: if I want to change the oil seal next week, do I need to drain all the oil again?

thank you.

*photo obtained from Land Rover Forum.


Click image to enlarge
Post #1073463 16th Aug 2025 6:49am
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Retroanaconda



Member Since: 04 Jan 2012
Location: Scotland
Posts: 2762

Scotland 
No. Depending on the angle you’re parked at you might lose a bit but you can just top it up if so. No need to drain the transfer box.
Post #1073464 16th Aug 2025 8:00am
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I Like Old Skool



Member Since: 23 Feb 2015
Location: Manchester
Posts: 859

United Kingdom 1994 Defender 110 300 Tdi ST Coniston Green
Think that picture is the 300tdi setup, 200tdi should be with the expander and adjuster on the left & right.

What did you struggle with? Was it getting the nut off, or pulling the flange off after removing the nut?

The flange can sometimes be a bit of a tight fit so may need tapping or even easier with a puller. There should be minimal oil loss, expect some, but no need to drain the box completely.
Post #1073467 16th Aug 2025 8:23am
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cykoh85



Member Since: 25 Apr 2022
Location: Selangor
Posts: 159

Malaysia 1990 Defender 110 200 Tdi SW Santorini Black
Retroanaconda wrote:
No. Depending on the angle you’re parked at you might lose a bit but you can just top it up if so. No need to drain the transfer box.


Ok, thanks for your info Wink
Post #1073468 16th Aug 2025 8:32am
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cykoh85



Member Since: 25 Apr 2022
Location: Selangor
Posts: 159

Malaysia 1990 Defender 110 200 Tdi SW Santorini Black
I Like Old Skool wrote:
Think that picture is the 300tdi setup, 200tdi should be with the expander and adjuster on the left & right.

What did you struggle with? Was it getting the nut off, or pulling the flange off after removing the nut?

The flange can sometimes be a bit of a tight fit so may need tapping or even easier with a puller. There should be minimal oil loss, expect some, but no need to drain the box completely.


Yes, the picture I shared earlier was obtained from another forum.

The one I took myself wasn’t very clear, but I’ve uploaded it now—please have a look.

I’m struggling with the nut, as it’s very difficult to remove. So I was wondering, is there a circlip around it, or any clip that prevents the nut from moving?

thank you.


Click image to enlarge
Post #1073469 16th Aug 2025 8:35am
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Retroanaconda



Member Since: 04 Jan 2012
Location: Scotland
Posts: 2762

Scotland 
The nut should just be a nyloc, but it will be very tight and the flange wanting to turn is a pain.
Post #1073482 16th Aug 2025 11:06am
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cykoh85



Member Since: 25 Apr 2022
Location: Selangor
Posts: 159

Malaysia 1990 Defender 110 200 Tdi SW Santorini Black
@Retroanaconda, Any idea how to remove it? I used the diff lock and released the handbrake, but should I also engage 1st gear?

It’s really tight 😓 and I still failed to remove the nut.
Post #1073485 16th Aug 2025 11:54am
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MarkBrown



Member Since: 03 Oct 2022
Location: Mid Wales
Posts: 558

Wales 1983 Defender 110 Other HT Auto Keswick Green
You can put some sort of bar above and below two bolts and turn the flange so the bar then jams against the chassis. It will probably bend the bolts and mash up the threads though, so you’ll need some new ones. 1983 110 automatic OM606
Post #1073486 16th Aug 2025 12:23pm
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Retroanaconda



Member Since: 04 Jan 2012
Location: Scotland
Posts: 2762

Scotland 
Put it in diff lock, first gear. Putting the drum back on and pulling the handbrake on might also help.

A 2’ long breaker bar should undo it, but if it’s not been off for a long time it may need an impact wrench or longer bar.
Post #1073489 16th Aug 2025 12:50pm
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htb2



Member Since: 02 Nov 2018
Location: Carmarthenshire
Posts: 548

Wales 
When refitting the oil seal is fitted flush with the casing or pushed in till it bottoms out?
Post #1073491 16th Aug 2025 12:59pm
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cykoh85



Member Since: 25 Apr 2022
Location: Selangor
Posts: 159

Malaysia 1990 Defender 110 200 Tdi SW Santorini Black
MarkBrown wrote:
You can put some sort of bar above and below two bolts and turn the flange so the bar then jams against the chassis. It will probably bend the bolts and mash up the threads though, so you’ll need some new ones.


Alright, I will give it a try and see. thanks Bruv!
Post #1073495 16th Aug 2025 1:58pm
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cykoh85



Member Since: 25 Apr 2022
Location: Selangor
Posts: 159

Malaysia 1990 Defender 110 200 Tdi SW Santorini Black
Retroanaconda wrote:
Put it in diff lock, first gear. Putting the drum back on and pulling the handbrake on might also help.

A 2’ long breaker bar should undo it, but if it’s not been off for a long time it may need an impact wrench or longer bar.


Ok, looks like I need to buy a long breaker bar, since I was using a normal ratchet with a metal rod.

Thanks Bruv!
Post #1073496 16th Aug 2025 2:04pm
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cykoh85



Member Since: 25 Apr 2022
Location: Selangor
Posts: 159

Malaysia 1990 Defender 110 200 Tdi SW Santorini Black
htb2 wrote:
When refitting the oil seal is fitted flush with the casing or pushed in till it bottoms out?


I want to know this too, waiting for someone experienced to answer. Very Happy
Post #1073497 16th Aug 2025 2:06pm
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MadTom



Member Since: 10 Sep 2013
Location: Olomouc
Posts: 677

Czech Republic 1999 Defender 130 Td5 HCPU Baltic Blue
Nylock nuts often get very tight over time, so realy big breaker bar and some angle plate with holes tightened to the propshaft flange and jammed to the ground should help. Holding it just by the gearbox is not the bets idea. "Drobek" = The Small One - Discovery 2, "Blufínek" = The Blue Thing - Defender 130, and for me at least Ford Mondeo Smile
Post #1073504 16th Aug 2025 5:01pm
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cykoh85



Member Since: 25 Apr 2022
Location: Selangor
Posts: 159

Malaysia 1990 Defender 110 200 Tdi SW Santorini Black
@MadTom - Ok, I’ll get the items first and try this method to see how it works. Thank you.
Post #1073538 17th Aug 2025 2:29pm
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