Mystery Fluid Leak

[OneSickS10]

Hey guys, as my girlfriend backed her TB out of the garage yesterday we noticed fluid on the garage floor. After looking around under the truck with the skid plate off I could only see 1 area where the fluid could possibly be coming from. I was under the impression that this was the 4x4 actuator motor but after looking at pictures of this part, I dont believe that it is. The part that I referring to is a black plastic motor of some sort, that is directly in front of the passenger side CV shaft, it has 2 bolts holding it into the diff. If you cut your wheels all the way to the right you can actually see it through the small V in the frame. I can feel it doing its thing when you change from 2WD to AWD and 4WDHI and so forth. Is there a gasket behind this part that could be causing this? I see no other spots where the leak could be coming from. I can provide a picture if necessary.

Thanks

[linneje]

Can you describe the smell of the fluid? The smell of gear oil is unmistakeable, if it is coming from the differential.

[the roadie]

That item is the front axle actuator, and it engages the intermediate shaft coming from the driver's side of the engine from the front differential. It pushes on a spring loaded plunger inside to engage a splined shaft, in all 4WD modes. There's a bit of grease behind that, but as other members have found out after the bearings fail, there is no constant oil bath or provision to regrease the splines over time. It's not a likely place to drip a lot of lubricant.

http://www.roadie.org/actuator1.jpg

Here's a picture of one removed, and there is a gasket, but it doesn't drip oil out of its mounting hole when the item's removed.

http://www.roadie.org/actuator2.jpg

It could also be a seal on the end of the CV shaft right next to it or deeper in on the intermediate shaft. Of a leaking/torn/loose CV inner boot.

You need to identify the fluid if you can. Spray degreaser around the area and clean it up, and then watch for it to reappear. Might localize it better. Here's a diagram of the parts in the area.

http://www.compnine.com/largeimg/010820TT06-103.gif

[OneSickS10]

That's exactly the part. Great photo and thanks for the exploded view that was awesome.

The strange part is that I couldn't get a distinct smell from the fluid, which right off the bat tells me its NOT diff fluid, we all know gear oil stinks BAD, plus it was red. I checked the tranny, and it was a tad low on oil. I cleaned it all up, but won't have the truck back here to check it until thursday night.

I checked to see if it was an axle shaft, I just cant see it being the shaft seal, there wasn't any fluid anywhere near that CV shaft.

[linneje]

Has to be tranny fluid then. You have to try and find where the leak is coming from. Anyone had a tranny fluid leak that would leak fluid around where he is describing?

[the roadie]

Boiling out the top of the dipstick, or being pushed out the top of an unlatched one, has been reported. One member even had a fire after it sprayed out. It could then run down to the front axle area.

[linneje]

I had never thought of that, but I had a Ford Escort that had exactly that happen when the tranny got too hot one trip. Definitely a good place to start looking.

[OneSickS10]

It was the transmission cooler lines. Right near the passenger side tire, just below the power steering pump the two lines are held together with a small plastic clip. I am assuming since the truck was from the upstate NY area with all of the snow and salt they have on the roads, it managed to make its way into the clip and just sit there and eat away at the lines.

I replaced the lines yesterday and so far so good. :thumbsup: Not the easiest job to do on your back but it got done. I ended up replacing both lines all 4 pieces. I don't want to EVER have to do THAT again! (Oh yea, I left that plastic clip out).