Fluid Leak Checks

NOTE: Verify that the leak is from the transfer box and not the gearbox before proceeding.

PRIOR TO ROAD TEST
1. Check oil level in transfer box is correct.
2. Check tightness of level and drain plugs.
3. Check breather system for blockage.
- To validate the system the pipe must be removed, inspected, rectified as necessary and installed.
4. Remove ail traces of oil from exterior of transfer box.
- Take vehicle for short road test.
5. Identify source of leaks and repair as follows.

FRONT OR REAR OUTPUT SEAL LEAKING
1. Drain the oil and remove the leaking output flange.
2. Inspect the seal track on the flange for surface damage.
- If damaged renew component.
3. Remove and discard the oil seal.
4. Inspect the seal locating bore and remove any sharp edges which may damage the new oil seal.
5. Install new seal.
6. Install the output flange and all the other parts.
7. Add oil to correct level into the gearbox.
- Tighten fill plug to 30 Nm

COVER PLATE GASKET LEAKING
1. Drain the oil and remove the leaking cover plate.
2. Remove all traces of joint sealant from both joint faces.
3. Degrease all components and apply a thin film of Hylomar sealant, to both joint faces.
4. Apply thread sealant to the bolts which come into contact with gearbox oil.
5. Install cover plate.

CAUTION: Care must be taken not to overtighten the fixings.

LEAK BETWEEN THE MAIN AND TRANSFER GEARBOXES
1. Site vehicle onto a ramp [hoist].
2. Select neutral in transfer box and select 4th gear in the main gearbox.
3. Run engine at 2000 rpm with the clutch/drive engaged.
4. Observe joint between the main and transfer boxes.
5. If oil leak is found establish if it is gear oil.
6. If so, the leak is originating from the transfer box.
7. Check the two inner (main/transfer) bolts are oil tight, as these holes are tapped through into the main transfer case.
8. Remove the transfer box to inspect the mainshaft collar seal track condition, and the front face of the transfer case for porosity.
9. If these areas require servicing, the transfer gearbox input seal must also be renewed.

CAUTION:
^ Avoid damaging the new seal lip and ensure the seal is installed flush with the machined face.
^ Also ensure the new seal is not damaged when installation the transfer gearbox.

10. If red A.T.F type oil is seen leaking during the workshop test, investigate the main gearbox for cause of leak.

DETENT PLUG OR ELECTRICAL SWITCH LEAKS
1. Detent plugs and electrical switches do not usually leak.
- It must be noted that they install into open tapped holes in the transfer case and therefore should be considered when looking for the source of the leak.