99 Disco II
Well got it out OK with no real issues for my first t-case removal. Pretty straight forward after reading a bunch of threads here. I found the wiring above the T-case and not knowing what and how it was all connected to be the hardest part. Good news is it surely looks like this was my issue after inspecting the case. You'll see in the pics that the bearing race on the tranny side is all mashed which allowed the gear to drop and toast the the larger gear in the middle of the case. Have one on the way from Marty at ichopimports.
I'll have some Tranny seal questions if someone can chime in who I can PM!
Thanks and if anyone wants step by step I can surely give it to you while it's fresh in my noggen

 

Way to get in there and tackle this repair yourself. 2 thumbs way up^^!!

I have had a small leak from my transfer case since I bought the truck. I had originally planned on taking it out and resealing it when I did my major 100miles service, but I didn't think I would have enough room to drop it out underneath without putting it on a lift. Were you able to drop it out without using a lift (just on jack stands)?

I would love some advice on how to remove it, the tricky stuff to look out for and whatever else you feel important. You can skip the obvious stuff like removing the cross member and drive shafts. I am more interested in the part about separating it from the transmission and the hidden plugs.

Also, you were talking about sealing it back up. I found this kit that I am going to use. I know that the RAVE says to use just RTV to seal certain parts of the T-Case, but this kit actually gives you pre-made gaskets to use. I think I will still use RTV along with the gaskets, and that should really insure a quality seal.
Transfer Box Gasket & Seal Kit LT230 (Part # RTC3890) - Land Rover kits from Atlantic British

 

Hey sure no problem! I'll take some pics and point out where I had some issues. I could certainly do it in half the time the second go round :_)
I pushed it into the garage with another vehicle and used 4 heavy duty jack stands on the t-peed jack points ( at least that's what i hope they are ) and left all the tires on for safety. I also rolled a decent size angled rock under the back tires to prevent any movement. I had the rover up with plenty of room to work ( and I'm a big guy) and get out the t-case with zero maneuvering problems. I did have a second set of hands to lower it down but did almost all the work myself. I used a variety of extensions and sockets but really just basic tools except to get out the corner t/case mounting bolt. I'll take a pic of that too and post! If u want to call me just PM me and I'll shoot u my cell.
Yes**** I was talking about sealing it back up. Should I change out the rear seal on the t-case ? ( I already bought the front flange and seal for the front drive shaft) , re-do the seals on the tranny ? ( i was told there are a couple u can do with the t-case off and the tranny in the vehicle ) and whatever else would make sense since there is now a ton of stuff out.......Cheers, Bob....

 

Bob,
The gasket and seal for the rear extension housing seem like they would be a piece of cake to change with the T-Case out. Although I'm not sure if they are necessary to change.

Here are the PDF's from the RAVE: Transmission seals to do with T-Case out.pdf

If it were me, I would replace every seal and gasket on the T-Case since you already have it out to work on. You should never need to pull that thing out again if you do it now.

 

I have found the oil shaft seal but not the casing gasket!
That was at Atlantic British....Guy said it was not coming up on their system so ???

 

I personally would not even mess with that gaskets. The picture in the Rave clearly shows a gasket, but I have looked all over and can not find a replacement.
I'm not sure I would even mess with the rear seal if it's not leaking. You know how to pull the T-Case now if you ever need to get at it in the future.

 

ok,,,got a big ice and snow storm so have not been under the Rover in a few days.
Will post some pics for you with descriptions ASAP .........Probably Just going to replace all the oil seals and permatex the rest......