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CLutch SLipping and Bell housing Wet

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TalonspoolAWD

15+ Year Contributor
156
0
Jul 9, 2003
I recently rebuilt my 92tsi AWD tranny and installed a new clutch. I had the flywheel resurfaced and put it all together and here is the deal. I filled the tranny with fluid from the fill whole with only the front jacked up. I hope that i did not over fill the tranny cause it would leak about a little puddle every day and i would have to add a liter to it about every 3 weeks. Then i jacked up the front and back and filled it through the fill whole until it ran out and i did not see anymore leaking. I am wondering i did not see a OIL pump inside the tranny that would cause it to build to much pressure from me adding to much gear oil. Since the tranny is leaking when i pulled it out to install a ACT 2600 i notice that the bell housing is all wet inside with a residue all over it, and my clutch is dead but i did not really see any fluid on the clutch, just the disc looked like it could have been wet. Where i am at now is that i have a NEW 2600 and everything is cleaned up, i am afraid to install the tranny back if a seal is leaking, I REPLACE ALL THE SEALS, THE ONE ON THE OUTPUT SHAFT AND THE SEAL TO THE TRANSFER CASE OUTPUT SHAFT. COULD MAYBE I JUST OVERFILLED THE TRANNYT SINCE IT WAS JACKED UP HIGH IN FRONT WHICH MAKES THE FILL WHOLE A LOT HIGHER THAN IT SHOULD BE.
Please let me know what you guys think, i really dont want to take this thing back apart and look at it because i think that its only cause i overfilled it but i am not sure if its possible
Thanks
Tom
 
I overfilled mine that way and it seems like im getting a leak from the output shaft as well. Do you have a part number for that seal?? Also you do have to pull the tranny to change this correct?
 
Turns out that the problem is that the little ball is missing inside the LSD that holds the output shaft from moving. Even though the transfer case is bolted to it the shaft can still move a 1inch left or right between the two and when it does it comes out of the seal.
Tom
 
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