just last week i bought a 2006 Mitsu Lancer Evolution SE and when i bought it the guy said all the fluids where flushed and put back in. including the transfercase. well when i went to go get the car he said that for some reason he thinks the T-case is leaking somewhere. he also mentioned that he likes to overfilled the T-case a little bit. when i turn on the car to warm up. the Tcase dont leak at all at nuetral. but when i drive the car and come home its running down the crack where the Tcase and the Trans meet. idk if its the seals between the tcase and the trans or if its running out the breather (wich i dont know where the breather is located). please help i dont want to have to pull the tcase if i dont have to. if anyone has pics of the breather or has any idea on what troubleshooting i should do please give me some help. should i pull the fill plug and see if any come out?

 

There is a rubber o ring seal between the t case and transmission if it is not lined up right it will leak and if you run your t case low on fluid it will destroy itself...fast not a cheap fix. Pull the fill plug and check the level. Plan to pull the t case and check to make sure the seal is intact and positioned properly.

 

+1 was there a clutch job done recently on the car? maybe he didnt replace the transfer case o-ring

 

/\ Or more than likely tore the seal when re-installing.

Aaron

 

i talked to the guy today. he said that he did recently changed the clutch and when he did he replaced the o ring but he forgot about the small one farther up. i guess ill prob start there. ill check the amount in and plan to pull it. ill keep you guys posted. and thanks for the help.

 

or the seal fell out of position.

 

Good luck with the fix!

 

called mitsu. they said they dont have the seal in stock right now but.i got it on order. im still planning on pulling the tcase to check both o rings

 

alright let us know how it goes!

 

i had this problem and it didn't take but 30 km's of driving before the tcase went KABOOM! And left with a 3000 dollar bill. fix this ASAP and dont drive till its fixed. My guess is an o-ring. Simply overfilling the tcase wouldnt cause a leak..but you shouldnt overfill either,

 

maybe a stupid question....but when i go to pull the TC out do i need to bleed all the fluids out?

 

no such thing as a stupid question when i did mine i just drained tranny fluid thats about it and tcast oil of course..otherwise youl have trasmission oil everywhere so just those two worked for me.

 

another question...when moving the TC over i wont have to pull the crossmember and the shaft out do i?

 

yupp! shaft must come out first, as well as the little end piece on the tail of the tcase connecting to it to the driveshaft, theres very little room to wiggle it out, also it will be way easier if you remove the cross-member. i highly recommend it because you may have to pry engine forward against the subframe so youl have more room to play with. And the CV driver side axle must come out too (obviously) lol

 

When I pulled mine with the motor in I just unhooked the back motor mount and used a floor jack to rock the engine forward and up enough to get the t case out. You might be able to get enough room to replace the o ring with out pulling the t case all the way out.