TNRR, I recently replaced two intermediate shaft 0-ring seals that were leaking - old ones were as hard as plastic. Recommend considering replacing the seal before putting the TC in, might save another leak in the long run.

 

that’s where my current one is leaking. Did you have to make a dummy shaft to keep the gear set together and have to redo the crush sleeve? I’m not sure if 04 t cases have that, but a video I saw on YouTube for a defender lt230 had that. Any more info you have on replacement would be amazing, unless it’s just all in rave. I was definitely gonna replace the Input seal for sure.

EDIT: found the overhaul manual online and the parts at rovers north. I'll defintiely order those up prior to install.

Did you go with new intermediate shaft bearings or reuse the old ones? any insight would be much appreciated. I've never torn into a Tcase, but seems simple enough. I might need a new torque wrench though. not sure I trust mine.

 

Took the nut off and pushed the shaft out only enough to get the o-ring off. Coated the shaft in the high torque silicone (stronger when cured - helps cushion the shaft in the housing which is known to wear out (steel shaft + aluminum housing=wear). Retighten with same nut 1/16-1/8 more. and peened the nut. Over the miles your transfer case has seen the bearings have loosened up and can take 1/16-1/8 more crush preload with no issues. It wasn't an exact science to begin with.

 

I installed @Extinct’s inline mod on Saturday. Super satisfying to see the average running temp drop from 208 to 180. Truck is running great.

Tonight I performed the @Best4x4 PCV Mod. The truck has some pretty seepy valve covers so my hope is that a clean breathing PCV prevents me needing to get them done any time soon.

New tires should be in tomorrow, ordered the Dick Cepek Trail Country AT/MT hybrid.

Considering a new Y pipe so I can sell the original cats and put a few $’s in my pocket for more maintenance and mods down the road.

 

Picked up a set of 16x8 black modular steels with a -35 offset & a set of 285/75 Special Tracks, mounted by hand as nobody local could mount them this week & so far have fitted the fronts. Rain and dark and pain preclude the fitting of the rears for now, and there'll be some chopping of arches to be done before we can actually go anywhere or turn corners lol. Looks tough though & should have another 4" or so clearance under the axles which is welcome...

Edit- further to that, went out at about 10pm & got the back wheels swapped over too, it just looked too much like it was squatted & I didn't want Whistlin Diesel to come and mulch the thing while we slept... Just ordered some +3" terrafirma rear shocks & extended stainless braided brake hoses too, that's the running gear pretty much sorted now just need to find a good deal on a winch & possibly some underside/body protection although we don't see much rocky terrain it's more mud round here...

 

Those are cool. Where did you get them?

 

They're from Goliath Off Road

 

Finally got around to installing the Ebay snorkel. Came out pretty decent. Super finicky to get lined up properly to the under the hood intake. Template supplied was waaaay off.

 

Thanks for the heads up! I had intended to use just standard fuel line. I’ll be sure to get tubing rated for higher temperature.

 

Did you have a lift already?