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5-spd trans leaking where drive shaft goes in, how to fix? 2WD '94 XJ

caspergotaz28

NAXJA Forum User
Location
Southeast, TX
It is flinging gear oil onto the cat, that's how I detected it. I would like to fix this myself if possible. I have access to air tools and have done fuel pumps, alternators, brakes.

After driving, it will drip at about the rate of one drop every 5 seconds for about 10 minutes, then slow down.

Can someone give me a quick how-to or point me towards a writeup. I have never taken out a driveshaft so if you could guide me through that too. Please don't tell me the whole trans has to be dropped though.

Here is a pic if anybody needs to see what I'm talking about....
http://www.mustangmods.com/data/10620/trans_leak.jpg

btw, this is a '94 XJ 2WD 5-spd.
 
Pretty easy really, I jack up the rear and put it on jack stands. If you get the rear up high enough, the oil doesn´t leak out the rear of the tranny (much) when you pull the shaft. Take the half round clamps, off of the bearing caps on the drivehsaft U-joints (mark the U-joint and yoke so it goes back together like it came apart). Hold the caps on with your fingers and push the driveshaft forward, the front yoke will slide a bit into the tranny so the U-joints clear the rear yoke (might have to pry a bit with a large screwdriver). Have some tape or something handy to take make a loop over the caps, so they don`t fall off, or you´ll be hunting for roller bearings. Pull the driveshaft to the rear and the whole works, will slide out the back of the tranny. Best to have a bucket under the back of the tranny and a rag handy just in case.
Pry out the old seal, coat the new seal outer rim (the part that slides into the bearing well), with a light coat of silicon sealer (after wiping the oil off with a little solvent, the cleaner the better the seal). Keep the seal as straight as possible when putting it back in. Various methods for reinstalling it, I use a small hammer and a small piece of wood and tap around the edges at first on opposite sides, then when it starts in aways, I tap it in a circle, a little at a time. So it seats, alowly and evenly, if you hit it too hard, it can bend the metal rim, on the seal (there is a special tool for this, that I´ve never seen). I´ve used a big socket, that matched the diameter of the seal to tap it in. I always grease the seal lip, with a finger full of grease, maybe not necessary, but why not, it would be a bumber, to have your new seal get hot, from lack of lube.
Also mentions in the book to try and get the front yoke, onto the same splines, that it came of, I never bothered, it never seemed to hurt anything.
If your new seal doesn´t last more than a few months, your probably gonna have to buy the tail cone. The bushing is in the tail cone and the book says the bushing is not replacable. Though if I ever did have a cone bushing go bad, I´d probably try and do it myself, bushings are cheep. I´ve done it on other transfers and trannys, not easy but doable.
Not a bad time to take a close look at the U-joints, if you can wiggle the caps left and right, it´s probably time for new U-joints. Bad U-joints can also cause the seal to wear quickly.
With the seal off it´s pretty easy to measure the play between the yoke and the bushing. If you push the yoke to one side, on a good bushing, I´ve measured about 0.003, between the bushing and the yoke, with a feeler gauge.
The bolts holding the half round clamps on the U-joint caps, have been known to snap off, loosen carefully and don´t over tighten when reinstalling. I seem to remember having a bit of trouble finding a socket to fit. I usually use a little dab of thread locker (mild) just in case, during reassembly.
 
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The only addition would be to check the yoke to tailshaft seal surface. If it is worn, it might cause the leak. I know on the harmonic balancer they make a sleeve and special seal for it. Just something to look at.
Tom
 
I have to correct my directions a bit, I should have looked closer. The removable tail shaft housing (and bushing assembly) is on the AW4. Most of my directions remain valid though.
 
In regards to pulling the shaft out, I am seeing four bolts on the rear section (adjacent to the diff.) They are about 3/8" hex bolts that hold some kind of a cap on the u-joints. I should remove these 4 bolts correct?
 
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