For those that didn’t catch the part numbers for the shaft o rings it’s,
FRC7439 - small o ring
FRC8292 - large o ring

Love the british inginuity of being able to re-use almost anything and everything to save a few pennies!

The dummy shaft is a pretty slick little idea

I'm just as imressed with the spam tin opener key on your loctite tube as i am with all your videos.  Great stuff Mike.

I've pretty much fixed my Disco just about looking at your videos - so, thank you :)

Gradually did it in with an impact.

Not everyone can repeat that one!

I have solved my defender transfer box leak very easy and cheap, it can be done "in situ", does not need to remove gearbox or transfer case. Remove the seats to gain access to gearbox from above. Loosen bolts which bolt gearbox to transfer box and separate them just to create crack between them. I have taken very thin brass sheet (0.10mm) cut shape to fit over intermediate shaft and left some excess material to stuck between gearbox and transfer case.
Clean the area a bit, smear some flexible adhesive, stuck the sheet between gearbox and transfer box covering the shaft hole. Tighten the gearbox bolts and wait a bit adhesive to dry before driving. This way brass sheet is held firmly creating a seal over the shaft hole.
It has worked for me beautifully, no leak for years! Before that I had to check and add oil on monthly basis.

Another fantastic video mate much appreciated, I have a question if you wouldn't mind helping me with what I'd the diameter and length of the Dummy shaft please ?

Kind Regards Rhys

Thanks for this video!
Is it necessary to use a dummy shaft?

Great vid ,what size is the dummy shaft I will be doing my disco soon

Hi, thanks for your informative videos, what size is the dummy shaft you are using?

Didn't see you putting in the sleeve,, what part of the process did this happen,,
Great video

Should the intermediate shaft have an o ring on the nut end aswell as the other end?

On one of your videos, you had a couple of studs in lieu of bolts. Do you have a part number or details for these? Thanks

Wonder whether replacing those rubber o-rings with Viton ones would have benefits? Must be possible to get the right size one, if they're always a problem!

PS some of the little bits where you pause the video and do something it'd be super useful if those of us who are a bit ignorant (ok just me!) were able to see what steps you took - maybe as a sped up section?  :D

One last question - when putting the squeezy gasket on do you leave it a bit to semi-harden before installing? Or install it basically straight away?

Thanks again Mike, great vids :)

from what i understand if you get to the point that you need to change the o-ring on the shaft, you will also have to machine it, because the collar on the housing would have widened a little bit due to play from the shaft. is this correct?

is there much up and down movement of the flange where the front  prop attaches .

Hey. Just wondering if you can chnage that O ring on the vehicle? Looking at mine even if i get the nut off the shaft wont come out the otherside enough to fit it. Does it need to come fully out the side the nut was on?

This may have been covered/answered before... One of the bolts in the front flange (that attaches the rear of the front prop shaft to the transfer case) has been stripped. Should I be taking the whole front flange off to get the replacement bolt put in the same way as the rest (by cutting out the old one), or is it alright to just put the new bolt in backwards to the rest (maybe reverse the rest at the same time to be consistent?)? Why are they reversed anyway? Thanks for the help!

do you know if it is possible to remove the flange (front)  with the transfer case in place?  One of the bolts to which the propshaft is attached seems to be bent and ideally should be replaced. not sure how it got bent but might be responsible for a vibration im feeling. i only noticed it since i removed the front propshaft in a bid to test if the vibration was coming from one of the propshafts. Without the front propshaft i did not feel the vibration.