Todays Project - What did you do today?

[Pete O]

I think I may have convinced the missus that there are possible uses for all these machines other than making parts for one another.
The transfer case in my Land Rover had sprung a leak (yeah, surprise...), there is an 'O'ring at the rear of the intermediate gear shaft that is very prone to leaking and involves removal of the transfer gearbox to fix it. I have a mate with the same model landy and his was leaking worse than mine, so I offered to do both in my workshop if he would help me, as it's a 2 person job.
The O-ring leaks because the lateral forces on the shaft cause ovality of the bore in the aluminium housing where the head of the shaft sits. I decided on a more permanent repair than just replacing the o-ring.
Enlarged the bore in the case by .600, made a bush from some 4140 with a .001 interference fit in the housing and .001 clearance on the shaft.
   
Heated the case on the BBQ and cooled the bush in the chest freezer, applied some loctite 620 and a simple puller arrangement
   
   
Put all new bearings and seals through the box whilst it was out, lot of work but now it's quiet as a mouse and not peeing oil on the ground. Only downside is that now I have to do it all again on my mates car. Nice to have the gear to do the job properly.