For 1990-2009 cars

### Diagnostic Aids

Using the incorrect type of transmission fluid may affect the sealing ability of the seals. Make sure the use of the correct type of transmission fluid. The incorrect type of sealer may not be compatible with the transmission fluid or may not have the correct characteristics for sealing the affected components. Make sure the use of the correct type of sealers. Refer to Adhesives, Fluids, Lubricants, and Sealers .

### Test Description

The number below refers to the step number on the diagnostic table.

1. Use an approved method to clean the transmission to make sure the leak location is correctly identified. If using a powder method or dye method, make sure the products are compatible with the transmission fluid.

Step | Action | Yes | No
--- | --- | --- | ---
DEFINITION: Visible sign of the transmission fluid leaking from the transmission.
1 | Did you review and perform the necessary inspections? Refer to Symptoms - Manual Transmission . | Go to Step 2 | Go to Symptoms - Manual Transmission
2 |

1. Inspect for the transmission fluid level higher than the recommended level. Refer to Transmission Fluid Replacement .
2. Adjust the transmission level if incorrect.

Was the transmission fluid level too high?

Go to Step 19

Go to Step 3

3 | Inspect the transmission vent for a blockage. Is the transmission vent blocked? | Go to Step 4 | Go to Step 5
4 | Repair or replace the transmission vent. Refer to Transmission Vent Tube Replacement Did you find and repair the condition? | Go to Step 19 | Go to Step 5
5 | Verify the location of the leak.

1. Clean the transmission assembly.
2. Operate the vehicle for 24 km (15 mi), or until normal operating temperatures are reached.
3. Visual inspect or use the powder method or dye and black light method to locate the leak.

Is the leak occurring at the drain or fill plug?

Go to Step 6

Go to Step 7

6 | Replace the drain or fill plug. Refer to Transmission Fluid Replacement Did you find and repair the condition? | Go to Step 19 | Go to Diagnostic Aids
7 | Is the leak at the transmission output shaft seal? | Go to Step 8 | Go to Step 9
8 | Remove the output shaft seal and inspect for the following. Refer to Mainshaft Rear Oil Seal Replacement .

• | Damaged or worn seal.

• | Damaged seal bore.

• | Improper installation.

• | Cracks in the component.

• | Propeller shaft yoke sealing surface is scratched, nicked, damaged, or worn.

• | Loose or worn bearing causing excessive seal wear.

• | Yoke flange nut loose.

Did you find and repair the condition?

Go to Step 19

Go to Diagnostic Aids

9 | Is the leak at the front of the transmission? | Go to Step 10 | Go to Step 12
10 |

1. Inspect for the leak at the input shaft seal.
2. Inspect for the following if the input shaft seal is leaking:

• | Damaged or worn seal.

• | Damaged seal bore.

• | Improper installation.

• | Cracks in the component.

• | Input shaft sealing surface is scratched, nicked, damaged or worn.

• | Loose or worn bearing causing excessive seal wear.

3. Replace the input shaft seal if leaking. Refer to Mainshaft Rear Oil Seal Replacement .

Did you find and repair the condition?

Go to Step 19

Go to Step 11

11 |

1. Inspect the case for cracks or porosity.
2. Replace the transmission front case half if it is faulty. Refer to Transmission Disassemble .

Did you find and repair the condition?

Go to Step 19

Go to Diagnostic Aids

12 | Is the leak at the backup light switch? | Go to Step 13 | Go to Step 15
13 |

1. Remove the backup light switch. Refer to Backup Lamp Switch Replacement .
2. Inspect for the following:

• | Cross threaded or damaged threads.

• | Insufficient sealant.

• | Leaking switch.

• | Improper installation.

Did you find and repair the condition?

Go to Step 19

Go to Step 1

14 |

1. Remove the shift shaft detent sleeve. Refer to Transmission Disassemble .
2. Inspect for the following:

• | Cross threaded or damaged threads.

• | Insufficient sealant.

• | Cracked sleeve or case.

• | Improper installation.

Did you find and repair the condition?

Go to Step 19

Go to Step 1

15 | Is the leak at the sealing flanges of the transmission case? | Go to Step 16 | Go to Step 17
16 |

1. Remove the transmission. Refer to Transmission Replacement .
2. Disassemble the transmission. Refer to Transmission Disassemble

Did you find and repair the condition?

Go to Step 19

Go to Step 17

17 | Is the leak coming from a crack or porosity in the transmission case? | Go to Step 18 | Go to Diagnostic Aids
18 |

1. Remove the transmission. Refer to Transmission Replacement .
2. Disassemble the transmission. Refer to Transmission Disassemble
3. Replace the faulty case. Refer to Transmission Assemble

Did you find and repair the condition?

Go to Step 19

Go to Diagnostic Aids

19 | Operate the system in order to verify the repair. Did you correct the condition? | System OK | Go to Step 1