Hey guys so I bought an Evo X last week and drove it like an hour and a half home. Has a service required light on so I get under the car and see the axle seal is leaking. I go to mitsu and get an axle seal and figure easy fix. So I go to drain the fluid and literally zero fluid comes out. Ok, so I replace the seal and and put it all together to find out the axle and output shaft have some play even with the new seal and everything popped in place. I pushed the axle all the way where it is flush and it just doesn't sit firmly in the t-case. I pulled apart again and pulled the output shaft hoping maybe the c-clip on the output shaft was broken but it wasn't. I put it back together hoping maybe there just is a little play on the Evo X's and fill it up with mitsu lsd gear oil(I've had Evo 8's and 9's before and don't remember any play).
I drive it around the block though and it feels really good but sure enough the service required light comes back on and I look in the rear ayc reservoir and its low again. So I fill it and I drive a little more and it's low again. So I top it off and park it over night to come out and again the reservoir was low so I look under the car and it leaked out of the axle seal again. Dont really understand why the t-case is leaking and the ayc reservoir is getting low since that takes ATFlll and the t-case takes the lsd fluid. Is there maybe a trick or does it sound like the t-case is shot? Any input would be extremely appreciated.

Update: I've been researching for days and just came across something that may make me think I installed the axle seal incorrect. I put it on the axle and installed it. Am I supposed to install on the t-case first and that's why I'm leaking and having play?

 

The seal your replacing holds back transmission fluid, not diff fluid, so for the love of God top off your trans when your done.

And yes, you put the seal in the tcase, then install the axle. It's easier to install the seal if you remove the shaft too. Put a thin layer of silicone on the outside of the seal before driving it in. Also, get another new seal. Also, since you've been installing the axle without the seal fully seated in the tcase, the axle probably has been properly locking onto the output shaft explaining the looseness.

Losing AYC fluid is an unrelated issue to this seal. So you actually have two problems.

 

Thank you for the reply. I guess I had a retard moment when installing the seal. Does the smaller lip of the seal go into the t-case or the other way around? Just making sure since I already ****ed up. Bought a new seal but it's been raining like crazy here in CLT so have to wait till tomorrow. Also I'm kind of confused does the seal only prevent transmission fluid from leaking or does it leak both differential and transmission fluid? Confused why transmission fluid is coming out of the t-case side. I only ask because the t-case was bone dry when I pulled the axle and I filled it with fluid and that's what leaked out of the seal after I filled it. I only assumed because it was not leaking at all in the driveway because I guess it was already empty when I bought the car and then when I filled the t-case it poured all over the driveway from sitting over night. I will however change the transmission fluid as well. Already bought the fluid from the dealer. Again thank you for the input.

 

So I replaced the seal and thought I got it in correctly but still leaking. Maybe went in too far? Still have a little wiggle. Thinking maybe the threads on the axle are not keeping it clicked on the output shaft?

 

Oops, forgot I was in the X section, disregard the trans fluid statement. The 8/9's "pump" trans fluid through sealed passages in the tcase into the front differential, which is sealed from the ring and pinion fluid. So on an 8/9, trans fluid comes out of that seal. The X's don't do that, so your trans is fine. You are only leaking transfer case fluid. Sorry for confusing you.

The seal has flexible rubber dust shield on one side, and is flat in the other. That dust shield goes outwards.

And even if the axle is fully installed, they still wiggle just smidge.

 

I don't understand.. If you just bought the car and found the issue, you bring it back to where you bought it from, tell them about the issues, and have them repair it for free. I wouldn't scuff my knuckles for anything like that for a car I just bought.

 

random, but do the axles have metal dust shields that fit over the seals? one of m IX axles had a dent in the shield that would push on the seal and let it leak.

tossing the idea out, just in case. LOL

 

I got the car knowing it needed some work so that's why I'm forced to fix It. Also buying a used car from a private party is always going to be an as-is transaction which I knew going in so I just have to fix it. I don't mind the learning experience as well. But just an update after messing with this seal I found out it is for sure leaking a lot of ATF fluid out of the axle. 100 percent sure it's red atf fluid. So I took the cover off the actual t case and inspected. I have a video of it but do not know how to upload through my phone on here.
I did order the seal from the dealer that goes inside the cover and the larger o ring.
http://www.jackstransmissions.com/co...-case-seal-kit
http://www.extremepsi.com/store/prod...at=1847&page=1
The larger seal I believe is the one that is non existent inside the cover on my car. Maybe burned up or something I'm hoping.

 

you did remember small o-ring that goes between the trans and t-case? is about the size of a nickel or dime. easy to miss if it falls out and you don't notice.

 

Evo X doesn't have that, main.

 

Hmm I didn't see any.. I didn't see any on the diagram either for what I took off. I didn't take the t case off the actual transmission though I just took the first outer cover off while it's still in the car.

 

The X does not have the oring Kaj speaks of. It's an 8/9 thing.

 

Nevermind LOL

The mobile app doesn't tell me which sub-forum I'm in LOL