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Home > Maintenance & Mods (L322) > Transfer case leak (2009 4.2SC with Magner Steyr DD295 box)

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fanders

Member Since: 10 Jul 2013
Location: Hants, UK
Posts: 321

2009 Range Rover Autobiography 4.2 SC V8 Buckingham Blue

Transfer case leak (2009 4.2SC with Magner Steyr DD295 box)

The new 4.2SC Rangie has an oil leak on the transfer case, spotted on pre-purchase inspection and some money set aside (£450) to fix, knocked off the asking price. Here's a couple of pictures of the transfer case:

I have no idea why the second photo is upside down, it did that when uploaded to the gallery and the crop & rotate picture tool there doesn't seem to work.

Looking at the leak last week it appears to be leaking from the transfer case face seal, between the two casing halves, as the input and output shaft seals are dry - but I'll have a closer look to confirm. I found RRPhil's DD295 teardown thread very informative:

https://www.fullfatrr.com/forum/topic12404.html?highlight=dd295

and from further reading on this forum, it seems that curing a leaking face seal it somewhat hit and miss, and sometimes leaks from other apertures on the casings can present as a face seal leak, requiring more than one go at curing the leak until the root cause was identified.

The reason for posting this was to ask what the consensus was on replacing the three input/output shaft seals at the same time the case leak is fixed (assuming that is the problem)? Since the transfer box has to be removed anyway, and the case halves split open, I think I may ask my Indy (Keith Gott, Alton, Hants) to do the shaft seals at the same time. But on the other hand, if the shaft seals are currently good, why risk disturbing them and introducing the possibility for a shaft leak? Thoughts welcome.

The shaft seals I'm talking about are items 14, 71 and 73 on the diagram below:

Cheers, fanders

23rd Sep 2019 11:49am

Joe90

Member Since: 29 Apr 2010
Location: Hampshire
Posts: 6424

Before going to all that trouble, I would:

Clean up the casing
Check the oil level (brim to filler hole)
Identify location of the leak
See if you can seal it from the outside

just my tuppence worth .
Experience is the only genuine knowledge, but as time passes, I have forgotten more than I can remember
Volvo V70 P2 2006 2.4 Petrol 170bhp Estate SE
MG Midget Mk1 1962

Previous: L322 Range Rover TDV8 3.6 2008; L322 Range Rover TD6 3.0 2002; P38A Range Rover V8 1999

23rd Sep 2019 1:26pm

fanders

Member Since: 10 Jul 2013
Location: Hants, UK
Posts: 321

Yep I should do that, will do.

23rd Sep 2019 1:52pm

fanders

Member Since: 10 Jul 2013
Location: Hants, UK
Posts: 321

Transfer case cleaned up with a good douche of brake cleaner, should be easy to track where it's leaking from now:

I topped the oil level up with the correct grade of oil, rather worryingly it took 0.6ltr (full is 1.5ltr) which probably means it's been leaking for ages.

25th Sep 2019 10:30am

Dexter00

Member Since: 11 Aug 2025
Location: London
Posts: 1

2007 Range Rover Autobiography 4.2 SC V8 Stornoway Grey

I think I have similar problem, what was the issue with yours? How did you fix it?

11th Aug 2025 8:35am

fanders

Member Since: 10 Jul 2013
Location: Hants, UK
Posts: 321

I 'fixed' it by the tried and trusted method of leaving it alone and monitoring - it seems to have fixed itself, so I am continuing to monitor. It's had an oil change since then as well, I change the transfer case and diff oils at 20k intervals. ---------------------------------------
2009 4.2 SC Buckingham Blue
2021 Hilux 2.4

11th Aug 2025 9:11am

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