Transfer Case removal with Pictures
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Mudding
Joined: Aug 2015
Posts: 193
Likes: 54
Having to pull the T-Case back out because the input seal was leaking was heartbreaking to say the least, but I made it through the project and appear to have finally got a leak free T-Case. My resealed oil pan still looks good so at the current moment I have 100% leak free 2001 Disco (knock on wood). I never thought I'd see the day. I hope my mistakes and pictures will help others complete this job successfully too. Now I'm off to the next project on the To-Do list 
Baja
Joined: Feb 2011
Posts: 9,298
Likes: 318
From: Boston Strong
VERY NICE
thx for the post it will come in handy.
thx for the post it will come in handy.
Having to pull the T-Case back out because the input seal was leaking was heartbreaking to say the least, but I made it through the project and appear to have finally got a leak free T-Case. My resealed oil pan still looks good so at the current moment I have 100% leak free 2001 Disco (knock on wood). I never thought I'd see the day. I hope my mistakes and pictures will help others complete this job successfully too. Now I'm off to the next project on the To-Do list
This thread helped me out a good bit on an 03 D2 with a completely blown out transmission, sheared off transmission/transfer case mounts, and a transfer case that was completely ripped off and just laying on the rear crossmember!
Yep I finished up today with the small stuff (linkages, electrical connections, and vents). Got the 03 D2 to move under it's own power for the first time in 3 years..
Next it'll need the exhaust repaired where the drive shaft made it snap in half, a rebuild on the master cylinder (pisses like a 2 month old baby boy), a new 02 sensor (once again destroyed from the drive shaft), then it will be all cosmetic/tune up related.
The only thing that fought with me was the torque converter bolts, and slapping the gear back into the transfer case. Once I used some putty in my 13mm socket the torque converter bolts were easy, and once I spun the gear 180 degrees on the transfer case it dropped right into place.
Great write up for sure and the pic's made it awesome.
Next it'll need the exhaust repaired where the drive shaft made it snap in half, a rebuild on the master cylinder (pisses like a 2 month old baby boy), a new 02 sensor (once again destroyed from the drive shaft), then it will be all cosmetic/tune up related.
The only thing that fought with me was the torque converter bolts, and slapping the gear back into the transfer case. Once I used some putty in my 13mm socket the torque converter bolts were easy, and once I spun the gear 180 degrees on the transfer case it dropped right into place.
Great write up for sure and the pic's made it awesome.
TReK
Joined: May 2011
Posts: 2,768
Likes: 396
From: kitchener, canada
I'm going to be taking my 99 disco I bought for parts the transfer case out. I still can't figure out if it has the locking diff. Can someone show me in one of the above pics how I can check if it's a locking diff while it's still in the truck. I don't want to waste my time taking it out to find out it's not a locking diff
