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Czar97



Member Since: 09 Jun 2025
Location: Michigan
Posts: 4

United States 2009 Range Rover HSE 4.4 V8 Galway Green
Transfer Case Leak - 2009

-Always had a drop hanging from bottom of transfer case. Never left a spot on the ground.
-Dropped all fluids and replaced all.
-Let transfer case drain for a day
-New plugs and copper washers
-Degreaser and scrubbed transfer case to evaluate the leak
-You can see from the pictures that the leak originates from somewhere up high
-Drips down between the horizontal aluminum (4) bolt mount and the actual transfer case
-The vehicle has not moved since the fluid replacement. It’s been on the lift for days just dripping
-Other pictures just showing how it’s stayed dry everywhere else
-Red outline just showing exactly what is wet with new fluid

Any ideas?
(Lots of photos below)
Thank you for your help.

Post #719471 9th Jun 2025 2:59pm
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Czar97



Member Since: 09 Jun 2025
Location: Michigan
Posts: 4

United States 2009 Range Rover HSE 4.4 V8 Galway Green

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Post #719472 9th Jun 2025 3:02pm
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BAZ8046



Member Since: 26 May 2023
Location: Chatham
Posts: 47

United Kingdom 2012 Range Rover Westminster 4.4 V8 Santorini Black

It's hard to see from the photos but they normally leak from the seal between the two halves.
There is no gasket, it just uses a sealant, and you have to remove and split the box to reseal.
Mine is dry on the FF but have had to reseal my LR4 transfer box before which is the same unit. 2012 TDV8 4.4 Westminster Santorini black
2016 Discovery 4 Landmark
2002 Defender TD5

Post #719480 9th Jun 2025 4:33pm
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Czar97



Member Since: 09 Jun 2025
Location: Michigan
Posts: 4

United States 2009 Range Rover HSE 4.4 V8 Galway Green

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I’ve added blue arrows to show what I can tell is that it’s coming from above and coming down and rolling both towards the front of the vehicle on the aluminum plate and collecting on the head of the rusty 10 mm bolt. And the leak also comes down on the back of the transfer case and rolls on the bottom towards the rear of the vehicle and collects at that one transfer case fastener that holds the 2 halves of the transfer case together. So I strongly believe that it has nothing to do with leaking between the 2 halves of the transfer case, but yet some sort of a seal where the transfer case and the transmission come together.

Post #719482 9th Jun 2025 4:44pm
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Czar97



Member Since: 09 Jun 2025
Location: Michigan
Posts: 4

United States 2009 Range Rover HSE 4.4 V8 Galway Green

Click image to enlarge

After I loosened the 18mm giant rubber mount and dropped the mounting plate (removing the (5) 13mm bolts) the problem became very clear. So I held a can of brake clean at full blast with a fresh wire brush followed with new rag cleanup. Got everything bone dry and clean. Then a few minutes later I noticed a glistening crack right where the horizontal and vertical surfaces of the transfer case meet. I circled it in blue. I assumed it was the full load of fresh fluid migrating through a crack. Also there looks to be a wad of rough area like a patch directly below by someone else. THEN I stumble across an article from landrovermonthly.co.uk talking about how a “botched repair will always lead to failure in this case for the transfer case.”. Everything (specifically where they discussed where the leak was coming from) was as if I wrote the article based on my findings on my L322.
I took the end of file and scrapped the rough stuff off. Came off pretty easily. Like a wad of corroded aluminum.
As of now: I’ve drained the fresh fluid to get it away from the crack. Soaked the area with brake clean and hit it with air to dry it. If it stays dry for 2 days… it’s time for a smear of JB Weld. Then let it dry for 2 days. Then load it up with the new fluid and roll with it like that.
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Post #719827 15th Jun 2025 9:43pm
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