Hello all,

A few months back I made a post about an odd grinding sound that my 99 Disco II was making.

Well shortly after winter hit and that project got put on the back burner.

This week I pulled it back out and after a few hours of looking I found out it was the front bearing on the Transfer Case. What made that bearing go bad you might be asking yourself???

1 fluid OZ of gear oil! I guess the other 2qts has stepped out for the weekend.

Anyhow.

I got a new transfer case well, new to me.

My questions are.

1. The person who sold me the TC power washed it, often I don't worry about power washing however I can see that some of the left over RTV is coming off from around the access panels and should you pull on the RTV it pulls off with little effort.

I'm that kind of person to wipe excess RTV off before letting it try so that kind of thing does not happen, should I remove all the access panels and apply new RTV or is that normal?

2. I don't see any leaks from around the shaft plates and the e brake rotor was dry do I don't think I need to pull off the plates for new seal but what do you all think?

4. Since I have it out I plan to replace the seal that's between the trans and TC does anyone have a part number for that seal?

5. What are the Torque Specs for the mounting bolts or does it matter?

6. Can anyone think of anything I should check or replace before I re install?

Thank you all for your help.

 

Personally, I would replace the seals, open the covers, have a look inside, and redo the RTV. It's so easy to do on the workbench, and so annoying to do once it's in in place under the truck.

When removing the transfer case, take good note of where each bolt attaching it to the transmission goes.

Test the switches on the new transfer case before putting it back under the truck. Make sure that the lock switch is well adjusted using a continuity meter. It's a bitch to adjust while the TC in in place. If one switch is broken, do no buy a Chinese knock off off ebay.

Make sure that the shifter cables/linkages are working well before putting the TC back.

Build a makeshift stand that will allow you to move the TC back up without the risk of damaging the new output seal on the transmission and on the TC input shaft. That TC is pretty heavy.

The torque specs are in the Rave.


Have fun!
Georges

 

Doesn't need to be "makeshift". The shop manual has drawings and specs for a transmission jack adapter to hold the transfer case.

 

If I may, I would like to also add that you want to be sure the new TC has CDL, as there were some that did not. (assuming you had it to begin with...)

 

You're right.

What I did is I bolted this plate under the TC, then cut steel rods and welded them in place on two angle bars on a motorcycle jack. That's what I meant by makeshift.

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A sensible precaution!

 

Lowest Bidder


very nice indeed

 

Hello all,

I replaced all of the seals both rubber and RTV, I installed a CDL from a Discovery I, removed the high/low shift lock actuator built a custom installed tool and put the new Transfer case in.

On my first attempt I had a fear I cut the input shaft seal after so pulling it back out to check I did in fact cut nick the so I ordered another new input shaft seal reinstalled...

Sadly, after my first drive I was sorry to find the input shaft seal is drip drip dripping one more.

So I did not rip it a second time I coated it in gear oil and installed it could this be making it leak?

Anyone have any options or ideas before I pull this all back apart?

Right now I'm running 75w90 should I try 85w140? Stop Leak? Toss the truck off a hill?

 

Stupid question but are you sure it's gear oil that's dripping and not transmission fluid? Could be that you damaged the transmission output shaft seal at some point.

Also was the tranny output shaft worn out where the TC input shaft seal rides on it?

 

When you had it apart did you check the gearbox output shaft to make sure it wasn't grooved where the seal rides?