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T 230 T Transfer case Disco 1 TDi manual

Old 11-18-2012, 08:12 AM
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Default T 230 T Transfer case Disco 1 TDi manual

After weekend camping and heavy 4x4 I heard a awful clank when turning sharp left.
Going threw the whole routine back home,stripping and inspecting left hub, right hub and later front diff without finding anything wrong.
Drained the oil from transfer case and found steel shavings and decided to drop Gearbox and transfer. This is not a 1 hour job !!!!
Opened the 3rd diff in the T/case to find both shafts holding the planetary gears broken and gears seized onto the shaft pieces still in tact.

My question: Why did the gears seize onto the shafts? (The case was full with oil).
I have received the new Shafts and planetary gears but old planetary is 8 toothed and new is 9 toothed. Will this be a problem.
I am replacing the sun gears as well.
Any tips and suggestions will be highly appreciated.

Discovery 1 TDi (300i engine)
Manual 5 speed R 380 gearbox
T 230 T transfer case
3" lift with Rotoflex rubber coupler replaced with U-Joint.

Attached Thumbnails T 230 T Transfer case Disco 1 TDi manual-transfer-gears-broken.jpg  
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