I bought my ‘02 SE about a month ago. It has 138,000 miles on it. With the help of this forum and a very smart friend I have taken care of the Three Amigos, put on a set of tires, an oil pan gasket, tranny fluid, filter, and pan gasket, plugs, wires, valve cover gaskets, and a set of 6 inch off road lights (just for fun). I say all this to preference my question. How difficult is it to rebuild the transfer case? My local independent Land Rover shop said worst case scenario I was looking at $1,110, with rear main seal $1,600. If it is something I can do I will. But if the thought is leave it to a pro I will pay to have it done. Thanks in advance for the help and advice.
(My "smart friend" has rebuilt several engines and is very mechanical, plus I have a full shop at my disposal with all the tools/equipment I may need.)

 

I cannot answer to the how difficult part, but here is something that might help:
http://www.landroverresource.com/doc...Box_Manual.pdf

 

Why do you need to rebuild it? Anyway, with an 02 or 03 with a bad transfer case, I'd look for a used transfer case out of something that has CDL, 1999 through early 2001, or a 2004.

EDIT: wait, talking about rear main seal, are you talking about having the transmission rebuilt?

 

It's not bad, just leaking a drop or two every day. I am taking the truck to Germany and they are pretty picky on their inspections. Just want to take care of it before I go. My indy shop said they could put the CDL in while they were in there.

 

Sweet thanks! This will make for good bed time reading to night and should help with my decision on whether or not to try it myself.

 

Whatever it takes to stop the leaking. Suggestions? The transfer case is leaking enough that it will not pass the inspection into Germany. I assume (I know I shouldn’t) that it must come apart and there are some gaskets to replace.

 

I guess it depends on where it is leaking. Atlantic British sells seals for the mainshaft and for output, and they also sell flange kits with seals, so maybe they get scored or damaged some how?

Seal Transfer Case Mainshaft | Range Rover & Land Rover transmission Parts
Transfer Box Output Flange Kit Rear | Range Rover & Land Rover transmission Parts
Transfer Box Output Flange Kit Front | Range Rover & Land Rover transmission Parts
Transfer Box Gasket & Seal Kit - 1987-1988 | Range Rover & Land Rover transmission Parts
Gasket Lt 230 Transfer Box Front Output Housing | Range Rover & Land Rover transmission Parts

 

Try this before you tear into the transfer case. Drain the gear oil.
Add 3.5 quarts of 75w/140 gear oil with a half bottle of White Sheppard Oil Stop Leak. Then immediately drive your car for 1-2 hours. I like Royal Purple Max Gear myself, but any brand will do. I would recommend synthetic. This has all but stopped my slow drip. I even removed the LARGE inspection plate and resealed it with "Right Stuff" Gasket maker, still leaked from the upper inspection plate. Now no more leaks with the heaver weight oil, and it quiets down the gears. MPG's have not changed with 75w/140 in all diffs

 

bosshogt, you said "all but stopped" your slow drip. Is it just seeping or is it leaking slightly still? I have to have it stopped or the Germans won't let me drive.

 

Mine is leaking from that big inspection plate, the fix is to reseal it with RTV.
Try sealing that first and then see how it goes before you start tearing the transfer case apart.