I had to remove the transferbox from my 2003 HSE7 disco II because the o-ring was bad and leaking gear oil. After replacing the o-ring, I have found reinstalling is a problem. Has anyone had a problem with the transmission spline not matching up to the transfer box? I have wiggled, shook and shaked it to death and it will not go. There is no damage but it has become frustrationing to say the least. Also, can you use 75w/90LS gear oil in the transferbox or does it need to be without the LS?

Thanks,

 

The portion of the output shaft of the transmission that goes inside the t-case is removable. Try taking it out, and putting the stub shaft and gearset in after the case is bolted up. The LS fluid will be fine, it just has a friction modifier in it, will not do any sort of damage or cause extra wear.