LR
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Gearbox & transferMedium severity

Rear transfer box output flange spline wear

Will get worse if left.

Symptoms

Clunk from under the vehicle on take-up, rotational play in the rear prop shaft at the transfer box output.

Likely cause

The LT230 rear output shaft and flange splines wear when dry. Land Rover later added a felt seal and the fix of greasing the splines.

Suggested fixes

Listed roughly in the order most owners try them.

  1. 1

    Replace the output flange and seal

    Fit a new output flange, oil seal and felt dust seal. Pack the splines with grease and torque the nut correctly.

    Difficulty:
    Moderate DIY
    Cost:
    £ (Under about £50 in parts)
  2. 2

    Replace the output shaft

    If the shaft splines are worn, the transfer box rear housing must be stripped to fit a new shaft.

    Difficulty:
    Experienced DIY
    Cost:
    ££ (About £50 to £300)

This is general guidance gathered from owner experience and workshop practice, not a substitute for a workshop manual or a qualified mechanic. Costs are rough parts-only guides. Brakes, steering and suspension work affects safety, so if in doubt have it checked professionally.

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