Clutch, Axle, Trans...WTF?

[Loxias]

Last week I changed out my passenger front axle. After getting everything together, took it for a spin and everything was fine. Two nights ago, I decided to adjust my clutch as it was engaging too close to the floor. Adjusted the rod and got it engaging where I wanted it.

Yesterday morning, on the way to work I pulled away from a stop light and the RPMs in 1st and 2nd started rising faster than my acceleration like the clutch was slipping. 3rd gear and on seemed pretty normal however. Acted the same way going home so I parked it today. I figured maybe I over adjusted the clutch pedal so tonight I re-adjusted it to put the engagement closer to the floor. While test driving after a round of adjustment I punched it in second and the RPMs skyrocketed but so did the speed gauge. RPMs shot to over 4g's and the speedometer went up to 50mph but the car was barely accelerating.

Anyone have any ideas as to what would cause this? The sluggishness felt similar to when my passenger axle/cv joint went out but I'm not hearing any noises from that area (not that I would be able to over the engine revving and the exhaust anyway).

 

[nfernotalon]

It sounds like your clutch is slipping.. does it do it in 4th or 5th?

Although if it was slipping id be just your rpm's going up not your speedometer.. hmm.

 

[Loxias]

Not sure if it does it in the higher gears or not. I was headed out to the interstate when the thing happened with the speedo and I didn't want to get stranded.

I'll have a little time to work on it this weekend so hopefully I can come up with something.

 

[absolute_DSM]

Go about 45mph in 5th gear and punch it. If the RPMs skyrocket, you have a misadjusted master cylinder or a bad clutch.

Are you sure its a drivetrain issue and you just dont have a boost leak?

Does it seem like an electrical thing where your gauges are going crazy?

 

[eclipsh]

If the speedo skyrocketed but the car didn't go any faster you probably didn't get the axle in all the way. The speedo gear is run off the front diff housing so with one axle not in and a weak VC for the center you could just spin the crap out of the front diff and go nowhere resulting in high rpms and the speedo going up.

If that is the case you'd better check your gear oil level once you pop the axle back in too. The cup should sit hard up against the housing when in all the way.

 

[Loxias]

Well, I found the problem...

Apparently while removing the old axle I ripped the axle seal. I checked the trans fluid level and didn't feel any fluid so I went and got some and started filling. When it was full (not quite a quart in), I plugged everything back up and let her down. Then it all started gushing out around the axle.

So tomorrow I'll hunt around for a seal and hopefully get everything back together. One concern I have is that the axle is currently spinning freely and it's still in the trans! Gotta finish pulling it out and see what's going on with the teeth. Hopefully the issue is contained to the axle itself.

 

[Loxias]

Looks like I was wrong about the axle seal. After getting most everything undone, I scooted under the car to see the axle sealed tight with no gear oil anywhere around. The drip was coming from further towards the center. I couldn't determine the source, so I wiped everything down and poured a little more oil in...

It seems to be leaking from the backside of the housing where the passenger axle plugs in. Could this be from over filling it? I'm honestly thinking there's an issue with the axle because it is pretty much turning freely at this point. I have the wheel off and I'm able to turn it without the axle 'catching'. Guess I'll continue to take the axle out so I can inspect it.

 

[absolute_DSM]

Did you pay attention to what Nick (eclipsh) said?

 

[Loxias]

Yes, his post is what got me to check the fluid level. The axle is all the way in and looks exactly like it did when the old one was in. There was absolutely no fluid on that side of the housing. Before crawling under I thought it was traveling 'around' the housing, but that's not the case. The leak is from the other side.

 

[eclipsh]

Loxias, there are no openings anywhere in that section of the housing besides the axle holes and a breather on the top side (pretty obvious if that is where it is coming from). If you have a drip coming from the rear passenger side of the housing it is either the axle or you broke a hole in your trans.

When you put the new axle in did you feel it "pop" into place? There is a ring on the end of the axle that has to compress to sit in all the way. You have to really jam it in to get that to happen. I usually unbolt the strut from the hub assembly and use that as a pry bar/sledge hammer to pop it in all the way. Even then I have to give it a pretty hard push to make it go.

Here is a test. If you can unbolt the strut and just pull the axle right out of the trans then it is not in all the way. Since you need to check the splines on it anyway pay attention to that. You should have to use a pry bar to pop it out of the housing. Unless you are a body builder pulling on it will not get it out if it went in right.

 

[Loxias]

Just so I don't have to retype everything, here's a link to my installation thread in case you're interested.

I did here the click when it finally went in and it definitely did not want to come out tonight, even trying to pry it out. I haven't taken it out yet because I noticed it was dry under the axle.

I need to check the vent and see if that's where the leak is coming from. There's not a whole lot of clearance and with oil dripping down on me I didn't want to stay under the car too long. Can I check the vent topside or do I need to be under the car to see it?

BTW...thank you two for hanging with me on this!

 

[Auto RS T]

The vent hole should be covered with a small black plug just for reference. It could also be missing though. This plug is on the rear of the transmission but on the top. It is close to where the speedometer cable goes into the transmission.

Are you filling the trans with all four wheels on the ground allowing the gear fluid to drain out of the oil level bolt hole?

 

[Loxias]

After more than a month I've finally gotten back to working on the car. I replaced the axle and oil seal tonight and I think I found the problem. After putting the axle in I noticed that I could freely spin the axle and I could hear some clicking noises like teeth trying to catch. Looks like my center diff is on it's way out. I jacked up the other side and turning the passenger wheel would turn the driver's side in reverse so it does catch.

I did jack up the driver's side as well and could turn the wheel and see the other one turning in reverse. After lowering the car, I could no longer spin the passenger axle. I slow cruise showed that it still exhibits the original issues, just not quite as bad.

 

[Loxias]

Found a (the?) problem and another one as well.

On a stroke of luck I decided to check the driver's side axle. Crawled under to see some shiny silver sticking out and the brace laying over. Pushed the axle back in...went to put the brace on and noticed a bolt had sheared off. No biggie, for now I figured I'd put a bolt in the other hole and test to make sure that was the fix. Found a bolt and started turning...after a few minutes of it not going in, I stuck my finger in the hole to find the bolt had broken off in this hole as well!

Now, thanks to my brother-in-law who changed the driver's axle, I can't bolt this thing back into place. Anyone else have this problem here and have suggestions for gaining enough clearance to get this thing out? If not, I'll probably start calling around to some shops and see how much it'll cost to get these things backed out.