So about 8 months ago, i had a rebuilt tcase installed because i was experiencing death whine. This install was done at a shop with a very good reputation on this board. The problem is that i have noticed a small leak coming from the transfer case. I dont know what to do because it is leaking from between where two parts of the case itself come together. It is leakng directly above where the drain plug is in the picture, to the left slightly. Its from inside the deeper groove. Ive come to the conclusion that this could only be possible if the case was improperly sealed when rebuilt.

I could continue to refill tcase fluid every 2-3 months as i am currently doing, or i was thinking of filling the gap with some type of silicone sealant. That is not the proper way by any means, and doesnt seem right seeing how i paid thousands less than a year ago for a properly working tcase.

I am not sure what to tell the shop since it was installed a little over half a year ago. I changed the fluid every couple months since its rebuilt. I didnt want shavings in there during break in, so ive been playing it safe. Also mitsubishi only sells gallons of diaqueen. My concern is that since its been such a long time, the shop will basically tell me it must be my fault. What would u guys do if u were in my position? Theres no way i coudlve affected the seal between parts of the casing itself by just doing fluid changes, but the time since it was installed seems like a good reason for the shop to tell me to go f myself

 

Also just to note, the shop only did the install. The tcase was rebuilt somewhere else. I wanted one built by shep, but it wasnt possible due to time constraints. I was assured the place that rebuilt it was just as good though.

 

You never know until talking to them. It could be a seal that failed or even the oring between the tcase and transmission slipped during installation. I would ask the shop before going any further on the internet.

 

Thats why i dont want to mention any names. Im not flaming the shop by any means, but i want to see what other people think because of the long time difference. I feel like the shop doesnt really have to do anything, but i dont see how i couldve caused the leak. I also dont want to put the silicone there because it would make a reason why tcase failure down the line is my fault, due to my half assed fix. At the same time, i havent been driving it the last week, and i still need to get to work. This means next week i may need a rental car as ive been using my gfs.

Edit: also if this problem can be fixed relatively easily, i would prefer to fix it myself over the long weekend because i just need a car to get around. My evo is my daily. It doesnt sound like its that simple though based on the seals u mentioned.

 

I think its worth it to check if its leaking directly from the fill plug or the drain plug. Have you torqued the plugs back to correct torque specifications every time you changed the oil?

Also did you overfill the t-case? Do you measure how much fluid you put into it?

 

The drain plug was my first thought as well. Ive replaced the drain and fill plug gaskets with new oem ones and torqued to spec. I also thought it may be overfill coming out of the breather, but to make sure this is what i did: drained and refilled with the car level on jackstands. I let it sit for a good 30 min to let it drain out the fill hole. Then i installed that and torqued to spec. I cleaned off the whole area, and let the car sit overnight. Then today i went out to see if i could pin point the leak.

When i press my finger against that groove, ill have a thin line of fresh fluid on it. Since its kind of a deep groove (u know what im talking about of u look closesly at that part of the tcase), ive been tossing around the idea of plugging the area with some kinda silicone sealant. I know its not really the proper way, but the groove is deep enough that it may work just fine. Kinda wanted to hear peoples opinions in that as well. I dont really wanna take my car into the shop and have them remove the t case just because of a really slow leak

 

In an effort to pinpoint the source of the leak, ive put paper towel in there. This way i can see where its coming from, instead of a wet seal and a small drop at the lowest point. Only a small drop formed over night, not enough to break surface tension and fall onto the ground.

Its a very small and slow leak, but as u can see from my pic, its enough to get my dp super dirty. Also, we all know how little fluid the t case uses to begin with, so i am being very careful about how i treat my drivetrain.

I am beginning to think that a good sealant could fix this rather than: pulling the tcase, opening the case, reseal, then reassembling. My concern is If oring part number 30289 from the 2nd pic is what seals this area. Otherwise, if its just metal on metal flanges with silicone compound between, some more silicone should work to fill in whatever gap just fine. Hoping anyone thats opened up a tcase can let me know their thoughts. Thanks

Ps this thread is kinda heading in direction of the Engine/ turbo/drivetrain section, but then almost everything falls under those categories. I guess its kind of a discussion about flange seals in general as well. Mods feel free to move this at will.

 

Who rebuilt it? I only know of 2 places that are reputable. Please provide the info so that others don't have this happen to them.

If I were u, I would go ask the shop. But they only installed it so it's not their fault. Problems should be addressed early. Just get some silicone and seal it. Fastest way, cheapest.

 

I would contact the shop that built it, since its not shep, most of us can guess who. They should be able to tell you why this happened and if you need to get the install shop the business for incorrect install or if something may have happened in the rebuild. I would not just put a band aid on it. That could cost you a lot more in the long run. Drivetrain parts are not cheap so don't mess around, get it fixed properly. More then likely they will not fault you since I have never heard of anyone getting a leak from the transfer case, well unless they blew a hole in it. lol my 2 cents.

 

Its not jacks or whoever that other shop is. Its some local place. I dont even know who rebuilt it actually. I dont want to drag names into the discussion though, at least not until i talk to the install shop.

And i def know the high cost evo drivetrains. I had to pay a shop for this tcase because i lived in an apt and couldnt work on anything myself. Lets just say i had to bend over and lube up. They hooked me up since i had my timing belt done at the same time, but labor on a tcase install is alot

 

I would talk to the shop who did the install and also the shop that rebuilt it and see what you can work out. If I had to guess I would say its the o-ring seal which is not a big deal other than the labor to get to it. Get it fixed right, dont silicone it.

 

Yes O-ring #30289 seals those two case halves together.

 

Thank you. I guess thats whats failing on my tcase. This really sucks because its all the way in there.

 

Oh... TRE or Shep, there are no others in my book and many others. Some local place doesn't cut it for me...although TRE is half an hour away from me.

 

Update: turns out the tcase cover itself was warped. The shop replaced the cover under warranty, and i paid for 2 hrs of labor, which wasnt too bad. Feels good to finally be able drive my car now. Its nice having good evo shops around that stand by their work.

Im not sure how an aluminum casting couldve warped though. My best guess is either it was improperly torqued, or it mustve experienced a lot of heat at one point.