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boxoftricks

Member Since: 06 Feb 2019
Location: Home Counties
Posts: 749

2011 Defender 110 Puma 2.4 USW Zermatt Silver

Oil Leak

I've developed an oil leak from the circled red area by the transfer box on my 2010 TDCI 110.

Click image to enlarge

I cleaned off all the old oil using brake cleaner and took it for a quick spin.

Not sure if it is leaking down from where the transfer extension case meets the transfer box as I always thought the transfer box was dry???? Or is it leaking from the inspection cover and being blown upwards?

Any ideas and suggested fixes?

10th May 2019 1:55pm

Retroanaconda

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

Probably transfer box intermediate shaft seal. A poor design sees the shaft wearing the housing oval and then the o ring no longer seals.

Fix is a steel sleeve fitted to the box housing and requires stripping the box to do it. Or just live with it, as it’s usually a pretty slow leak.

10th May 2019 2:09pm

boxoftricks

Member Since: 06 Feb 2019
Location: Home Counties
Posts: 749

Thanks, it is leaking a few drops after each run is my guess. Is the steel shaft a specialist machine shop job or can a standard garage fix?

10th May 2019 2:18pm

MK

Member Since: 28 Aug 2008
Location: Santiago
Posts: 2489

2007 Defender 110 Puma 2.4 SW Chawton White

Another less bad scenario is that the oil is coming through the female thread of such bolt. I would give it a try with a bit of teflon. Puma 110" SW

.............................................................
Earth first. Other planets later

10th May 2019 2:53pm

blackwolf

Member Since: 03 Nov 2009
Location: South West England
Posts: 17911

2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

boxoftricks wrote:
Thanks, it is leaking a few drops after each run is my guess. Is the steel shaft a specialist machine shop job or can a standard garage fix?

Machine shop job, or Ashcroft Transmissions.

10th May 2019 8:12pm

Millerdark

Member Since: 16 Sep 2015
Location: Berkshire
Posts: 26

2010 Defender 90 Puma 2.4 XS CSW Fuji White

Transfer Box oil leak from t/box to G/box housing/mounting

Click image to enlarge
I’ve degreased all around the housing and the leak is not coming from above the highlighted area. I checked around the intermediate shaft area and it’s dry. I’m going to remove the bolt and apply some hylomar hylosil. MK has suggested that the oil may be tracking through the bolt hole threads. However I need to drain the t/box oil before hand.

Has anyone else has this type of leak? What was the fix?

13th Aug 2025 5:35pm

custom90

Member Since: 21 Jan 2010
Location: South West, England.
Posts: 20939

I think MK could be correct there, and your Hylomar suggestion is what I was going to suggest so I think that well worth giving a go.

Usually touch wood, it is often the most simple things, it could possibly even be that the fixing has become just slightly loose, the Defender trans has a significant amount of vibration so these things are common.

____\We|Will|Win/___
____/🇬🇧🇺🇸\____
_//*⛽️🛢️⚙️🧰*\\_

13th Aug 2025 9:29pm

custom90

Member Since: 21 Jan 2010
Location: South West, England.
Posts: 20939

P.S. If you were going to drop the oil, you could change the filler and drain plugs for mag types, if you wanted to unless you already have them.
As this is a perfect time to do the swap. ____\We|Will|Win/___
____/🇬🇧🇺🇸\____
_//*⛽️🛢️⚙️🧰*\\_

13th Aug 2025 9:33pm

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