I have an oil leak from the o-ring on the intermediate shaft of the transfer box situated mid-way between the input and output shafts.

Has anyone changed this o-ring with the transfer box in situ? How do you do it? I have the parts to do the job but am fearful of a bunch of gears falling out once I withdraw the shaft, and I live deep in the sticks so I can't afford to immobilize the vehicle by wrecking the transfer box.

 

As far as I know, the only bits of the transfer box you can replace with it in situ are the front and rear output shafts, bearings and seals. Everything else is a box out job.

Have you asked this question anywhere else? If not I can relay your Q to another forum I know of, as a gearbox expert, I'm not

Cheers,