2G 2G AWD Manual Chasing Down a Leak - between Transfer Case & Transmission HELP

[1greyawdtsi]

Per the title. After a bunch of initial & ongoing research I'm looking for some experience/opinions please.

I developed a slow drip, drip, drip, leak between the bell housing and transfer case. It does not drip unless I have been actually driving the car and when pull it in to the garage and park it over fresh cardboard. This Talon is not my daily driver. So upon discovering the leak, I have been going at the leak via the process of elimination POE.

After observing it not leak while running, stationary and then adding adding dye to the engine oil - I believe I eliminated engine oil. Next I added dye to the transmission & drove Talon for about 600 miles over a couple weeks, collecting the leaks in my garage on clean cardboard. After collecting and checking a series of leaks, I did Not detect dye in these leaks. So the only thing left without any dye is the transfer case that I run Red Heavyweight Shockproof gear oil in.

Today I pulled the downpipe, transfer case and flywheel inspection cover and shined a black light/dye detector light into the bell housing and I'm not seeing any dye on output shaft seal. Also there is no oil on the back of the flywheel. I also removed the fork window rubber piece and I removed the bellhousing front most rubber breather and there is a little oil on the back of the ACT pressure plate and a little oil around the shift fork, rubber boot and window and in the bellhousing around the output shaft area but no trace of dye.

I am leaning toward the transfer case (receiver/input) seal leaking. While I am aware of the rear of the transfer case being prone to leaking mine is bone dry and I replaced that seal years ago. Both axles seals are dry and no leaks from above are detected.

So anyone have this seal on the transfer case leak before? I am looking for thoughts on what this seal leaking looks like or if there is anything else to check. I despise the idea of replacing the front most transfer case seal, re-assembling it and still having a leak - as part of me just wants to keep going and remove the transmission for a more thorough examination, BUT maybe I did get lucky and it is just that T case seal leaking.

As always reading and thoughts are appreciated, thank you!

Several pics from today. Area were leak is. Couple pics of the amount of oil I'm seeing. Not a lot but still not great!

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[pauleyman]

I dont know what the big deal is. The transfercase seal is cheap and 5 min to replace with the tcase on the bench. I'd do it just because you can.

 

[1greyawdtsi]

I dont know what the big deal is. The transfercase seal is cheap and 5 min to replace with the tcase on the bench. I'd do it just because you can.

I def agree. Back story is installed this used transmission, transfer case w a new clutch about 1 thousand miles ago & car sat for 1.5 years before that looking for a used trans. Apologies I'm slightly agitated that I can't pinpoint the direct source of the Fy€#ing leak. I do appreciate the cool headed & straight forward response - thank you.

 

[TerminalTalon]

Replace the output for the drivers side axle. That explains the bellhousing full of fluid. Also check the others when you pull the transmission. If they haven’t been done do them while it’s out especially with an unknown transmission sitting.

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[jed344]

Generally when i see bell housing wet like that its from rear main but you have confirmed it's not engine oil. You also have confirmed it's not trans fluid as that would have been my next guess too. I do not think i have seen a t case leak from input side but anything is possible. 99% of time its output and clearly that is not what is going on here.

I would say try input side on t case. I know the struggle over last 15 year's of leaks with these car's.

 

[1greyawdtsi]

Generally when i see bell housing wet like that its from rear main but you have confirmed it's not engine oil. You also have confirmed it's not trans fluid as that would have been my next guess too. I do not think i have seen a t case leak from input side but anything is possible. 99% of time its output and clearly that is not what is going on here.

I would say try input side on t case. I know the struggle over last 15 year's of leaks with these car's.

Exactly. I'm not seeing any dye in the bell housing anywhere. That's basically what I was thinking. It seems unlikely that the input side seal of the T Case would leak - but based on low volume of the leak, zero dye and where it's wet - I guess it could be the T Case seal. I ordered a new seal. At this point I believe I will just Install it, reassemble it and see what happens. I will update this post ASAP, thanks!

 

[1greyawdtsi]

Update: I replaced the transfer case input seal. Still the leak persists. I will pull the transmission and see where the leak is coming from.

 

[1greyawdtsi]

Resolved. The leak is definitively coming from the manual transaxle input shaft seal. Should be fun replacing this seal along with the output shaft & rear main seal. Thanks again for your input (no pun).

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[pauleyman]

input shaft seal is inside the trans. Consider the play in the input as part of this repair. Check the axial play before disassembly. I would be it's a lot.