Hi Everyone,

Looks like I have a odd leak from my transfer case, 2004 Disco II with 79K miles. I've got a silver dollar sized leak from the transfer case, I can see a visible drip forming on the flange for the front driveshaft.

I've changed the fluid a while back with synthetic 75-90 and just now seeing a leak. The truck has been sitting a while since we have a newborn in the house and time to work on it is sparse.

I have a vibration at 70mph+ and have changed/looked at all items except output flange our output shaft. Has anyone seen a oil leak like this before? I think it could be the front output flange seal but that doesnt look like I can get to it with the case still in the car.

Any suggestions?

 

Actually you can. there is a writeup for it somewhere on here or even if you google it, you will find it.

on second thought. God said, let there be a write-up
https://landroverforums.com/forum/di...bearing-37670/
And it was good. Follow the link.

 

With the vibration, assuming you have replaced or rebuilt the front drive shaft already, then I would say you need a front flange seal and possibly a new flange if it has a grove or wear on it.

 

Remove and check your axle breather to see if it is clogged, if it is excess pressure will build up in the diff and cause a leak.
Its free to check and a great place to start, if it is fine you are out nothing but time.
Then move onto the seal.

 

I think Spike is talking about the transfer case breather, rather than the breather for the differential. I agree with his plan, as long as you check the transfer case breather tube, and not the axle breather tube.

Edit: and have you checked your wheels for balance for the vibration at70+?

 

Thank's

 

Thanks Spike. Stupid question but where do the breather lines (xfer case, front and rear diffs) run on the body? If I remember the front diff goes somewhere near the firewall, correct?

I've got a new flange kit with seal on the way, trying to fix this pesky vibration. So far I've balanced the tires (new tires at that, Hankooks ATMs are pretty good BTW), rebuilt and balanced the front drive shaft, replaced the rotoflex, checked motor and trans mounts with no luck; the vibes start at 72 and go away around 80. We don't drive this fast but wanted to see if and where the vibrations stopped.

Thanks for everyone's input, much appreciated. Now if I could ever get the skid plate I paid for from Bottorf Fabrications I'd be set (not holding my breath btw)!

 

Front diff, transfer case, and transmission breathers all run up the firewall. The rear differential just runs up into the right rear wheel arch.

Edit: on my 2000, one of the breather tubes did not terminate at the firewall. Instead, it made a loop at the firewall behind the engine, and returned and terminated over the transmission. It was either for the transfer case or the transmission. I removed the loop, pulled the tube free and terminated it at the firewall along with the other breathers, along with running a longer breather from the rear diff to the firewall.

 

Update- I resealed the transfer case plate and went to take off the nylock nut holding on the front flange- It was finger tight! I compared the splines on the stock and new flanges and they were worn pretty bad.

Just got home from a test drive and the damn thing still vibrates at 72 mph, now it even has a small vibration around the 35-40 mph mark. I have yet to pull a driveshaft, lock the CDL and go for a test drive; I was convinced that this new flange was going to be the fix after all this work.

Im open to any and all ideas or suggestions at this point, I'm frustrated beyond words...