Transfer case is from a Defender, but as I learned the D2 uses the basic same design (LT230 with slight internal modifications). Steel shaft sits in a hole of the aluminum housing. The hole wears out and leaks. I assume the D2 transfer case has the same problem (I have a slight leak from that area, not sure if it is the shaft, could be the input shaft as well).
And here is how it gets fixed by installing a steel sleeve in the hole.

I just saw it in the video, I didn't do the fix myself. Unfortunately you have to take the transfer case completely apart and need a good machine shop to fabricate and install the sleeve.

 

That's not really required, although you do have to separate the tcase from the transmission. I think I made a post on this but if not here is the short version. Mark nut and count number of turns when loosening. Do not remove the nut completely to keep the shaft from falling down in to the transfer case. Tap the shaft out until the large end of the shaft is exposed and you can remove the o-ring. It will be hard and quite difficult to remove because of that. Once off clean the bore and shaft with some brake cleaner or other high flashpoint solvent. You can replace it with factory or a more modern silicone o-ring you find at an autoparts store assortment. Once you have a new one installed coat the entire larger end with Permatex High torque silicone https://www.permatex.com/products/ga...et-maker-5-oz/ Remove the nut completely noting the number of turns. Coat the small end with the same silicone. Re-install the shaft and tighten the nut 1/4 turn extra. The silicone will isolate the shaft from the case and dampen the vibration, eliminating further wear due to fretting. It will also fill the gap and prevent leaks.

 

kind of a newbie question...does my D2 have a separate transfer case that needs to be maintained? and how do I know what transmission I have without pulling the pan?
Update....well crap.... guess I ll be servicing those as well.

 

Yes, tcase and transmission are separate and use different fluids. Tcase is notorious for leaking, slow enough not to fix because you have pull it, fast enough to cause damage over a few decades. You might want to consider this: https://extinctmotorsports.com/land-...l-sight-glass/

 

You should check the transfer case and diff levels every oil change, I do mine every 3 months just because I am OCD.

 

Why do you seperate the TC? Not enough room to work? I'm about to attempt the O-ring replacement on the Intermediate shaft. I think I can do it without separating it (famous last words)

 

the Geniuses that designed the interface made sure that the flange on the back of the transmission overlaps the head of the center shaft halfway so you can see it but you can't remove it without separating the two. Personally I think that particular engineer should be fired and blacklisted from the industry. And his boss and anybody in the chain of command that approved that abomination.

 

Love it