Hello friends, have a 2003 Disco 2. My transfer case has started a slow leaking from the front output shaft seal (front driveshaft). I bought the seal to replace, though when I opened the transfer case fill plug, gear oil spewed out. I'm suspecting the my breather is clogged. I read another thread which described three breathers next to the inertia switch on the passenger side bulkhead. I looked there, cannot find the breathers though there are a couple vacuum/breather lines behind the right side of the engine, just under the valve cover. I uncllipped one and its a loop, no end in site - I still think these are the transfer case and front diff breathers, guessing a different design for 2003/2004 or previous owner did some mods to it.

I'm thinking the banjo bolt might be clogged. What is the easiest way to access the breather which is at the top of the transfer case? What if I take apart the gear shifter transfer case shifter area, will that give me access to the top of the transfer case?

Thanks in advance

 

There should be 2 breathers on an O3 at the right side bulkhead

 

Maybe someone overfilled transfer case, not that unusual. Folks raise rear of vehicle higher, while filling, to get a few more spurts of fluid in there. I'd not assume the vent is plugged, just because excessive fluid drained out, especially, since you weren't the one that filled it. As mentioned, there are two vent tubes on passengers side on engine, one loops back towards rear of vehicle and end is not visible by firewall.

 

The two that go up to the firewall, one is transfer the other is transmission I think. They commonly get melted shut off the manifold when detaching from the firewall causing pressure in the boxes.

 

Yes, you can access the top of the transfer case if you remove the central console. That's a big job though, and you will also have to drill out the rivets that hold the cover plate in place. Probably a lot more productive to try and trace the breather, even by feel.

 

Thanks for the advices, I was able to unclip the two hoses, one has a looped end and does not look burnt. Second picture is from my spare engine showing the clip for the two breathers.

I've owned the disco for 5 years so was the last one to fill the transfer case (serpentine belt tool FTW). When it overflowed I did check the fluid while hot, just got done driving, would that affect the level? Other possibility was that it was on a two post lift and depending on where I place the arms the disco can tilt back a bit. I might be jumping to conclusions regarding the breather hose - could simply be the front output shaft seal leaking.

 

yes those are the breather hoses for t-case and transmission - they often fall from the firewall down onto the exhaust manifold and melt shut causing pressure that can blow all the oil out

 

I think your supposed to check it cold

 

Good news, loosened the bolt on the upper left side of the transfer case (sometimes used for a temperature sensor) to relieve pressure (if any). Fluid still trickled out slowly. Disco up on the lift is slightly tilted back. It must have been a slow leak. I followed the breather from the top of the transfer box as best I could, doesn't look burnt anywhere. Most likely just the front output seal leaking.

Also greased up the front driveshaft while I was down there