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Discussion Starter · #1 ·
So for those that haven't read my previous posts, I had my transmission rebuilt in January this year. About two weeks ago I noticed it had started leaking transmission fluid onto my driveway. I took it back in to have them look at the leak under warranty (18 month or 18,000 mile) the found the right transaxle output seal to be defective and replaced it. It was fine until today when I noticed it started to leak again. I talked with a transmission expert from their shop and they say if it is the same seal again it might mean there is a problem with the front axle of the car which would not be covered under warranty.

How does the transmission connect to the front axle in a way that it could cause a fluid leak?
 

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The trans has what we call axle seal on the side of the trans case at the final drive unit.. Axle shaft plugs into the drive unit, the seal is to keep the ATF from running out.

Inner CV joint seal surface could be damaged, they knocking the spring off back of seal that provides mild lip tension to the shaft surface, they not pay attention when installing axle back into trans, deforming seal when install, that is why we at HYUNDAI franchise have special service tools for install of seals, poor quality aftermarket seal not from an actual HYUNDAI contracted supplier.. too many variables

Take your pick.
 

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You have to remove the axle to replace the seal. So...they had the axle out twice and didn't inform you of a problem?
 

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Discussion Starter · #4 ·
Well I'm taking it in Monday for the leak because that is the soonest I can afford to take it in. Does it really require the axle to be taken out to replace the seal? They didn't inform me about it :/
 

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Discussion Starter · #6 ·
I jacked it up today to take a few photos of where I could find transmission fluid.
[attachment=18011:p_00051.jpg]
In the top right corner you can see a drop of fluid in relation to the exhaust.
[attachment=18012:p_00052.jpg]
A closer shot.
[attachment=18013:p_00054.jpg]
Another location of leaking fluid.
[attachment=18014:p_00056.jpg]
Three holes that I'm not sure are supposed to be there...
 

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Discussion Starter · #7 ·
Got it back. They replaced the right transaxle output seal again and polished down the axle. They say if it leaks again there must be something wrong with the metal in the axle because the seal was fine. Is there any truth in this at all?
 

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QUOTE (nick944 @ May 17 2010, 07:44 PM) index.php?act=findpost&pid=323765
Got it back. They replaced the right transaxle output seal again and polished down the axle. They say if it leaks again there must be something wrong with the metal in the axle because the seal was fine. Is there any truth in this at all?
There may have been some ware marks in the axle, that is possible, but if the seal was fine...why did they replace it? A more likely explanation would be either the seal wasn't the right one, had a defect, or it wasn't installed correctly.

I hope that takes care of it for you.
 

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Discussion Starter · #9 ·
Honestly I'm not sure why they replaced it again, they are Hyundai seals so they should be the proper fit.
 

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QUOTE (rsquared @ May 17 2010, 09:17 PM) index.php?act=findpost&pid=323798
There may have been some ware marks in the axle, that is possible, but if the seal was fine...why did they replace it? A more likely explanation would be either the seal wasn't the right one, had a defect, or it wasn't installed correctly.

I hope that takes care of it for you.
I don't know of anyone that re-uses a seal when repairing a leak like that, whether the seal was still good, bad, or indifferent, it's so cheap in the scheme of things that it's not worth taking a chance on the old one.

The seal could have been installed wrong (not hard to do if the installer was inexperienced or in a hurry), it could have had some sealant inadvertently smeared on the rubber during installation, it could have had a manufacturing defect in it, etc., etc., but once you pull the seal, it's so distorted you can't re-use it even if the rubber was still good.

The axle shaft could have had a groove worn in it from the previous seal, it could have had a defective finish, it could have been "bad metal" (pitted, poor quality, but this would be extremely rare to have the odd shaft of poor quality steel), but the machinist that polished the shaft should have been able to spot that type of problem. I would suspect that the groove was overlooked and caused the second leak, I have a chev impala that's prone to that type of wear on the harmonic balancer and the replacement seal kit often comes with a micro sleeve to repair the grooved balancer (I just changed the seal and repaired the balancer to stop a front seal leak this last weekend).

Another leak would certainly drive me to replacing the shaft as well as the seal again.
 

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Sometimes the axles get rusty or somehow marked up with burrs or ridges and the seals won't seal in the given situation. It's a good idea to replace the axles if they are known to be old and funky. Of course the guy who gets the bill doesn't want to hear that.

The other thing it could be is that these axles have snap rings on them to hold them into the trans. A lot of other car brands the snap ring is optional. In my Elantra, it wasn't. I put my axles in without the snap rings once, and gear oil would gush out when going around turns. I had to remove the axles and replace the snap rings. Your mechanic probably wouldn't tell you if he forgot the snap rings.
 

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QUOTE (jsinton @ May 18 2010, 07:40 AM) index.php?act=findpost&pid=323926
Sometimes the axles get rusty or somehow marked up with burrs or ridges and the seals won't seal in the given situation. It's a good idea to replace the axles if they are known to be old and funky. Of course the guy who gets the bill doesn't want to hear that.
Good point, I keep forgetting the shafts are exposed.
 
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