I have an 02' Disco and just got an 04' transfer case with locking differential. I also have a leaky rear main seal.
I am going to reseal the transfer just to make sure and then install.
How difficult of a job is it to fix the leak at the same time as installing the transfer case.
Can this be a one person job as I do not have anyone to help me with it?
Any special tools that I will need?

 

A rear main seal is between the engine and transmission, so you'll have to also take out the transmission which adds considerable time to the job.

 

You were planning on removing the transmission?

Might try a treatment of White Shepherd (now part of Blue Devil I think) rear main seal product (and there are others). They work by swelling up the rubber seal, and are usually pretty good.

Reading thru the RAVE shop manual is always a good idea before picking up the wrench.

 

I tried the Blue Devil rear main seal and this didn't help at all. As I understand it, I am going to have to drop the transmission to install the transfer case anyways, so might as well take care of the rear main seal while I have it down. About how long of a job would this be? Or would JB weld works or something else before I do this?

 

You do not need to drop the transmission to install a different t-case.

 

It could be your rear main or possibly your Cam Plug which is directly above the main seal. I just had my engine out and would have bet it was the Main Seal but turned out to be leakage out of the cam plug.

If you are pulling the Trans you don't have much more to do to take the engine out and do some painless preventive such as head gaskets. I've done the HG's while the engine has been in the truck and out of the truck and it is 10 time easier will the engine is in a stand.

 

These tasks can be one person jobs - with the right shop space, tools, etc. Tranny jack, etc. Here is one thing a member fabbed up to allow transfer case handling, he used an old inspection plate.

Maybe try the Bar's rear main seal fix? It would have to be a big leak, oil is cheap, and I park on sand....

 

I have to say using and old inspection plate as an adaptor is a fantastic idea.