transmission fluid lueak between trans and Transfer case

[AlphaAssault]

backstory: a few weeks ago, i replaced the transmission fluid and found that there was only a coffee cup full or so of fluid left. the transmission still shifted fine, and there wernt any shavings (i baby the trans in this car) so i filled it up and didnt think much of it. yesterday, i took my car for a spin, and unlike my trips to school, this trip lasted long enough to warm everything up. anyways, i get back and notice some oil had soaked into the pavement. i look under my car, and after much searching, squirming, and cleaning, i found where the fluid was dropping from.

problem: i cant find the actual source though. im almost positive its trans fluid, because the fluid was yellow in color, and i dont think regular motor oil could get to where this substance was. here is the best pic i could find of the transfer case; the dot is where the fluid was actually dripping from, and the yellow line is where i found the oil. my question is, what part of the transmission that is above the middle of the transfer case would leak fluid? i could see the flywheel, and there wasnt any fluid on or around it, so it must be coming from somewhere else. what part am i looking at replacing?

 

[knochgoon24]

The fluid was yellow? Have you checked your transfer case fluid level yet. My transmission fluid is red. Not sure what color the stuff you added was.

 

[cano86]

if its yellow in color sounds more like motor oil than transmission oil. If it is motor oil it could be the seal behind the flywheel, or if it is tranny oil it could also be the tranny seal as well

 

[architechnik]

There are some O-rings where the shaft comes out of the transmission, where that shaft goes into the transfer case, and where the drive shaft goes into the transfer case on the other side. Any of these can and will go bad eventually.

Have you checked the fluid level in the transfer case? You can use a straw or tube that will leave a mark. If it's pretty full, then it's probably the seal that comes from the trans. You'll need to empty both, remove the transfer case, and replace that seal.

 

[AlphaAssault]

Im using penzoil syncromesh trans fluid, so that stuff is yellow. isnt there an axle that connects to the trans somewhere just above the transfer case?

 

[architechnik]

The driver's side axle does connect just above around the same point that the transfer case attaches. It could also be that seal, but if you haven't done anything with it, then I'm not sure why it would suddenly start leaking, especially with it being at a higher point than the transfer case. It is a similar connection, though, but the opposite of the transfer case (male to female connection with axle inserting into transmission).

 

[AlphaAssault]

now that you mention it, a while back i had to replace an axle, and we had trouble getting the axle apart from the halfshaft (the halfshaft being the link between the transmission and the outer axle). the axle had frozen in the halfshaft. what are the chances that, while trying to pull the axle out of the halfshaft, we actually pulled the halfshaft out of the transmission some? does this sound probable? if so, would simply pushing the halfshaft back in remedy the problem, or do we think the seal @ the trans is bad?

 

[architechnik]

Well, the half shaft doesn't actually separate from the outer axle without going at an extreme angle. and then it's a greasy mess.

It actually all comes out as one piece after you remove the anchor/bearing (a bracket holding the half shaft to the block) and pull the other end out of the wheel. It then just slides out from the trans. If you pulled it out of the trans, then that bearing bracket will be pushing the trans out of skew. It's hard to do anything with that thing in place unless you didn't have the bolts incorrectly (both bolts, one with spacer, and torqued).

If you remove those two bolts attaching the bracket to the block, then it should give some play back and forth as the pivot point can then move around. If you pulled it out part way, then shoved it back in wrong then you definitely bashed that seal. Consider you're car is nearly 20 years old and that rubber is probably on its last leg if not already dead.

This makes me realize how many times I've removed the damn thing.

 

[AlphaAssault]

yea, we definitely tried to pull the outer axle out without removing the bracket or the inner shaft. we yanked pretty hard on that outer axle, and only after vigorously pulling on it without success did we try prying (where the outer axle meets the inner shaft) with a chisel and hammer. the thing that now has me thinking is that the half shaft, more than likely, never got pushed back in all the wat; because we didnt discover, until today, that it had ever moved out of the transmission. is all this adding up to a trans fluid leak, or is there something that isnt adding up. if we come to the conclusion that it is in fast the inner shaft, then ill take care of it tomorrow. but id like to be pretty sure thats the problem first, you see.

 

[AlphaAssault]

well, i took my car to the shop to see if they could pinpoint the leak, which i suspected was originating around the axle seal, and they told me they didnt see any leak in that area. they managed to find the tiny-ass oil leak from the oil pan though. im not sure what to think anymore. i guess ill run out there and see if i can find anything else out.

i also contacted the local dealership to see if they would at least inspect the transfer case for leaks, telling them that there was a recall on the part, but they ran my vin and said that the only OPEN recall on my vehicle was for a seatbelt. does this mean they never received a recall for the transfer case, or that they acknowledge there is a recall, but it has already been performed on my vehicle?

 

[architechnik]

The transfer case recall was on the check and drain plugs, not on the actual transfer case. That recall was open years ago, after the cars hit the streets. If it didn't leak within the first few years of driving around then you were alright and didn't need the recall.

That recall is no longer OPEN because all the faulty ones would have surfaced and replaced some time ago. If you suddenly found one of those drain plugs and seals faulty it would not be within the manufacturer's expected duration anyway.

There is a rubber plug thing on the top of the transfer case that is supposed to vent air when it heats up. The expansion would otherwise bow out the seals. If the case was overfilled then it will also blow out fluid. You could do a quick test on this by driving it around for a while to heat it up, then on a level surface remove the check/fill plug. If it's too full then some of the fluid will come back out so have a pan ready. This is how I always make sure that it's at just the right level: fill to brim, drive around, remove fill plug and let excess pour out.

 

[AlphaAssault]

doesnt the transmission have a vent plug also? i havnt messed with the transfer case at all, so i doubt it would all of a sudden start leaking. however, if the vent on the transmission is around the back, and the transmission got overfilled, it would vent fluid. i just dont know where the vent plug on the trans is. if this is the case, and the trans was overfilled a little, would it vent out and leak down onto the transfer case, or is the vent plug not in a position to leak onto the t-case?

 

[ohnoz]

Actually at this moment, Im removing the Tcase and Trans to replace the rear main seal, as I was pulling the driver side axle from the Trans, it most certainly leaked everywhere once i began pulling it out, so I would guess your axle seal needs to be replaced, might as well order some new seals for your Tcase since it will be off.