My car started to leak transmission fluid out from the driver side seal, about maybe a week ago. So I went and picked up a new seal, part number MD719710. I dropped the transfercase, pulled out the half shaft, took my time pulling out the old seal, and replaced it with the new one. I compared them side by side and they looked the exact same.

I installed everything back, put fluid, and after the second quart, I noticed the leak had come back...

When the half shaft is bolted to the block, it leaks. However, when the half shaft is not bolted to the block, and is hanging a tad lower it doesn't. Also, the shaft does not seem to be in the transmission all the way. However, even unbolted and everything, it won't go in any more.

I feel somewhat annoyed, maybe somebody can shed some light on this.

Pics:

Sounds like maybe the shaft goes in too far. Do you have the starter plate installed?

Dude, there is like a 1/8" gap on the top of the seal in pic 2. Either that seal is the wrong size for the shaft or you have an angle problem. Seals don't work very well when there is air space around them!

Also make sure you clean-up the sealing surface on the HALF SHAFT with scotch brite or equivalent. After a couple 100k the shaft actually wears a bit and the new seal won't work unless you polish it back up. But that assumes you get the first part straightened out!

^ That's actually the side not the top. It's the side facing the front of the car. And yeah I cleaned it up well before installation

And Rob, yes I do. Actually, I feel as if the shaft isn't going in enough :s

Definitely not in far enough and crooked. Tighten up the carrier bearing. Or is the tranny pushing away from the engine?

It was, the tranny happened to be lose. So I tightened all 4 tranny bolts, and the shaft appeared to line up a little better. It still had an ever so slight leak, so I decided to take it for a test drive. Sure enough, it got warm, parked it for 40 minutes, and about 1/4 litre, if not more, leaked out...

Is the car off the ground when your filling it?

Looks like it leaking 'cause the shaft isn't oriented correctly as everyone mentioned. Guess the question is: WHY is it not oriented/seating correctly? Could be alot of things I guess. You'll just have to roll up your sleeves and check everything out.

If you "happened" to found loose tranny bolts, I wonder what else is loose or not right on that car. Thats why its hard to figure out problems on the internet. A pic of where the intermediate shaft bolts to the engine, and how you have it bolted up could be a more worthwhile pic

do you have the a/c bracket or spacers between the intermediate bracket and block?

Yeah it is.



Ooh I've had my sleeves rolled up every night after work under it. All I know, is that the trans is bolted up all the way, the carrier bearing is bolted up all the way, and it's still not fully perpendicular.



From what I know nothing else is lose. I'll take a few pictures of the carrier bearing being bolted up when I have it apart again.



The A/C bracket, no, however I have used a wide variety of washers, all with different combinations for different thicknesses.

I used to have the same issue, I was also using a bunch of washers, new seal and the ac bracket re-installed and no more leak.

Use part # MB297732 if you don't want to cut the corner of the AC bracket off.

I actually have one of those on my desk in front of me if you'd like me to measure it. Now where is my damn caliper...

Did you grease the seal before installing the shaft?

the spacer thickness is 7.95mm. It goes on the bolt closest to the t-belt between the block and bracket.
The other gets no spacer.

Did you have them equalling to ~8mm or were you just eyeballing it? Was your shaft on an angle too? (lol)



Thanks Reza



Can I haz?



Yes, I made sure the surfaces were clean, and greased.



Thanks for the exact thickness Robert. I did some research and I found it's ~8mm.

I'm really looking forward to getting rid of this leak.

After filling the trans again and driving it for a little bit, once warmed up, it leaks a drop every 3 seconds.

It's for the ELHS I will install on my FWD someday (still have to fab a spacer for the seal).
That being said, you need it urgently while I can always just get another one at my leisure, so it's all yours!
Send me a PM or give me a call tomorrow, I'll bring it with me to work and we can figure it out.

^^^
True DSM'er there!

Yeah, he's a hell of a good guy!

Okay, so I took it all apart and got some pics and videos. I ordered two of the axle seals, just for good measures. I am also getting the OEM spacer from Rob, so that should leave one less variable.

Here's some pictures of where we stand:

This is the transmission bolted to the block. All 4 bolts are tight, and you can also see the starter plate.







Next up, is the carrier bearing.



Here is how I had it spaced



And the washers I was using, which came in really close to 8mm.



I also noticed my carrier bearing had some play. I'm not sure how much/if any is normal, or what effect that could have, but here is a video of it:

http://www.youtube.com/watch?v=4XGQNb4MdpY

Here is the spare AWD trans I have with a spare shaft. I took this video to show the play between the shaft and transmission, which I believe is normal?

http://www.youtube.com/watch?v=TibEtQyNLXM

Alright boys, looks like all she needed was a new seal and re-adjustment. Took everything apart, put everything back with (another) new seal, and 2 days, not a single drop leaked.