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Discussion Starter #1
Hi. Yesterday, upon inspection after smelling burnt fluid on the exhaust, I noticed that I have a leak in the rear transfer case. There does not appear to be a leak around the drive shaft, as it is dry above the motor (?) in the below pic. In fact the highest it appears to be wet is around this motor, which I think is the clutch motor.

You can also see that the bottom of the case is wet and this is forward of the clutch motor, which leads me to believe that the leak is not originating at the clutch motor.

Any ideas on how I should diagnose the problem or recommend a seal to replace?

Until I fix the leak I will need to make sure that I keep up the fluid level in the case.
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Discussion Starter #2
Does anyone have part numbers for the transfer case and clutch motor gaskets?

I guess I’ll start there. Can I put dye in the case oil to identify the leak location?
 

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From memory, there are no (paper) gaskets. The two casings halves are joined with sealant and the clutch solenoid shown in your photos has, I think, an O-ring. I’ve never come across anyone who sells replacements, though.

https://www.rangerovers.net/forum/6-range-rover-mark-iii-l322/41233-magna-steyr-dd295-transfer-box-teardown.html

https://www.jpat.co.uk/uploads/1/0/3/5/103549764/2018landroveritcpla.pdf

Phil
RRPhil - that is one great right up on tearing down the Magna Steyr DD295 transfer box.

My my only concern with opening my case and resealing to stop the leak, is the removal and reinstall of the clutch solenoid. You state that it should be energized for removal and reinstall to engage the fork. Do you have any other words of advice to a newbie who’s about to undertake this task?
 
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