Transfercase leaking!!!! PLEASE HELP!!!
it's a pain in the @$$ but you shouldn't have to remove the TC all the way. I replaced my transmission without the TC ever leaving the car. there's not point since its just one o-ring anyways. use a little bit of oil to hold the o-ring in place that should work. you'll have to drain both the tranny and TC before you do this. the TC uses like half a quart roughly. good luck! 
You can see the breather, its veiwable it has a peice of white plasitic on it. Id start there, if it dont leak when its just sitting, its possible he over filled it. Mine did that too but it only leaked at high speed thus hitting my exhaust and making the best smell in the world 
UPDATE: i started by taking both tires and brake assembly off followed by both axels. on the drivers side there seems to be something that slides in the axels to turn them. i got the one on the driver side out with a puller and i figured you wouldnt need to take the one out on the passengers side. i also dropped the exhaust followed by the driveshaft but i did forget to took off the piece that the shaft slid into. also havnt took off the crossmemeber yet. i emptied out trans and TC not sure what i should use for replacement.....any ideas? also is there 5 bolts holding the TC to the trans? or is there more? so where i sit is the bolts are broke loose and i can pull the TC away from it. hopefully i can get to that tomorrow. please if you think im missing something please double check with me. thanks again.
Use diaqueen for the Transfercase only. Please take clear pictures of where the leak is coming from underneath the car. I rebuilt my own transfercase and all I can say is I should have done this myself from before it would have saved me alot of headaches dealing with b.s shops in the past.
A lot of people run the stock recommended Diaqueen however there are other options. I run Redline's Shockproof in the t case and Redline MT 90 in the transmission. It works awesome, however I think I will be switching to Amsoil they make some really good stuff. I recommend you check out syntheticengine.org they can get you a great deal on any and all fluids you need for your Evo.
i personally use redline MT-90 for tranny and 70W90 redline for tcase and i have no complaints..as for the crossmember and tail i dont think removing them is necessary anyway since ur not completely pulling it out..and there is a total of 6 bolts holding tcase to tranny. there is a very long one furthest from the rest (near the acd pump) on the top of the tcase.
i just got done pulling the TC. what i found was no small o ring at all in the TC....and to me it looks like the area around the seal is kinda damaged..... in the pics you can see that the seal area looks scuffed up a bit. obviously it would affect the seal of the o ring. but any help would be great. how would i go about fixing this. or do you think that it will be fine?
and the problem with this is that i dont have anything to go off of. the TC was already leaking without the o ring and i would hate to go ahead and but the o ring in area and it still leak. any idea on what i should do?
yes, it would be a PITA if you did all that and it still leaked afterwords..personally you went that far i would go a little further and remove the tcase to get a closer look, maybe get confirmation from someone else and re-install it with all new o-ring..but in reality, if there is no o-ring there thats probably 99.9% your only problem.
UPDATE: the o ring should be in today. so im going to try and seal it. my other problem i have is i ordered amsoil and it wont show up till next week and if i get it fixed tonight i want to put some kind of fluid in the trans and TC to check it. should.i go buy cheap **** just to see if it leaks? i would hate to have to drain out the exspensive amsoil because the leak wasnt fixed. and if im going to use the cheap ****. what should i use?