Im almost 100% sure this tranny needs a rebuild

here are the symptoms,

1st gear shakes ( i can feel it in the shifter knob )

drivers side axle seal leaks ( ive replaced it as did the PO )

half the oil pan ( the side closest to the tranny ) is covered in oil -- and it doesnt smell like engine oil -- im not loosing any engine oil at this time either, level is spot on, on the dip stick -- looks like it is possibly coming from the bell housing but the shield is in the way -- ill be removing that if possible to view inside the bell housing to confirm oil is leaking from the input shaft seal


5th gear from the rpms of 2000 up to 2800 hums and even vibrates the entire car
yet at the same speed in 4th gear no vibrations so its not the tires or alignment -- i run a tire shop so not the issue in that category

when the car starts there is a light clunk coming from below my feet somewhere

both axles have been replaced and are new and clunk is still there when the car is started

AND when i take off in 1st gear every time there is a clunk below my feet if i could isolate it, id say transfer case tranny area

transfer case has been rebuilt by shep about 40k miles ago
fluid is great in it and no whines whatsoever

been doing my research all night whats my best rebuild option -- going for stock
shep? jacks transmissions? any other vendors you guys recommend ?

thanks for the help

 

1st gear shake is a problem unless the clutch is chattering. Vibration in 5th is not right but many '03's do it. The clunk noise could be many things. The axle needs a seal or maybe the wrong axle is installed.

 

axles are installed correctly and there the right axles as well, popd right in actually and went smoothly during install

another symptom im getting is that i cant engine brake with this car. if im coming off the highway and keep the car is 4th gear and let the the engine go down through the rpms, i get nasty ( what i think ) flywheel chatter

sounds like the cars falling apart --
and with fluid coming out of two spots in this tranny, probably on borrowed time


im getting a click when starting in first, almost every time i start at a light or stop sign,

I get a click backing out of my parking spot

I get a click also when hitting the brakes

all coming from the spot under the floor boards - id say right in the middle of the car under the shifter


ive checked all the subframe bolts there tight
makes me wonder whats making the click honestly because now its happening when i brake

whats right under the shifter/ dash that could be shifting and making this noise? possibly the rear motor mount?

 

Some (probably most) axles from parts houses that don't specialize in Evo's are the wrong axle from what I've read (no personal experience). Anyway, there are some horror stories on here of people who couldn't get the axles to seal and turns out they were installing the wrong part.

Yeah, you identified the location of the rear motor mount. Since it is difficult reach it could be loose.

It sounds like your clutch is toast but some multiplate clutches can be noisy and this is normal. Maybe check what clutch you have. Since you have a leak in another place it could be the little transfer case o-ring. I'd suggest you keep tabs on the oil levels in these boxes or it is just going to cost you more when you send them off.

As for the noise when stopping and starting I have that too. In my case the rear brake pads are too short. This is a common complaint but there is nothing to be done other than changing pads.

 

what you might have is a plated front differential installed there