oil leak diagnostics

[quest49s]

Here's the story, I have an oil leak on my front case somewhere and I've narrowed it down to the oil pump sproket seal. It will not leak at idle but if pull and pin the throttle cable so the rpm is steady at 3k It will just start dripping. It will drip a drop about every second.

I can see the oil run down from under the oil pump sproket and down the seam of the oil pan until it drips to the ground. I figured the oil pump sproket seal was blown so I got a brand new one and put that in.
Still had the leak.

So then I figured that the drain hole for the oil behind the sproket was plugged by something. Took off the front case and oil pan and sure enough I thought the Napa oil pan Gasket was blocking the drainage of the oil out of the sproket gulley. Cut out the chunk of gasket which was where I thought the block passage was and slapped it all back together. Still leaking.

So now I am stumped. The only other things I can think of are

1) my oil pressure is to high,
My oil pressure at 4250 and above is 100psi and up(10psi is as high as the gauge goes). At 3500 it's at 75 psi and 2k it's at 50 psi. I Have a brand new oil pump housing, oil pump gears, and front case. My balance shafts have been removed and I am running a "cyclone" oil filter housing with Setrab oil cooler w/ 8-an lines. With such high oil pressure maybe the small drain hole can not evacuate that much oil down into the pan, so the only place to go is out the seal and onto the ground!

Or

2) the "Star Cap" above the Sproket is leaking(the cap on the Front case that is on the out side of the oil pump). I consider this doubtful but I'll have to check it out when I get some more spare time.

Thanks for any input,
Jon Hebbeln
I don't have money to dump mobil1 syn. 10w30 in twice a weak

 

[quest49s]

Forgot to say that it was a 1991 Tsi AWD M/T (not that drivetrain really matters in this case).

I'll see if I can't find a digital camara and get a picture to draw out what I'm talking about.