My truck is broken. (help please) (kind of long)

[jeopardy98]

Hey all,

I met up with a fellow board member this afternoon to switch out some cash for some new rims. The drive was about an hour at 70-75 MPH. I drove there with no problems and when I parked and got out I noticed a terrible burning smell coming from my truck. Naturally, I popped the hood and out bellowed a little smoke. Very long story, somewhat shorter, I discovered that there was "fluid" leaking on my catalytic converter causing the terrible smell. There was also a very small puddle of "fluid" on the ground under my truck. Further inspection determined it to be gear oil and since I have a manual that means transmission fluid.

I'm taking it to my dads shop tomorrow and throwing it on the lift to see what I can figure out but in the meantime I was hoping someone might have some insight because I am pretty stumped as to where the leak is coming from.

I have checked all the usual culprits:

drain bolt is tight.fill bolt is tight.
no seepage from the seal where the bell housing meets the flywheel.
all the oil I'm finding is further back from the differential so it's not that
I cleaned all the dripping oil off the bottom of the tranny casing and fired it up to see if it would leak again and didn't notice any new pools on the bottom. I've determined that the leak is coming from somewhere on the top of the housing. I even looked from the top into the bottom through the firewall and did not see any liquid. The only thing that we could think of that seems to make any sense is that the case actually cracked somewhere but what in the heck would cause that?

I drove the truck 70 miles home with no other ill effects and when I parked it, it dripped all of one single drip. Does anyone have any clue what I should be looking for once I get it up on the lift tomorrow? I really would prefer to not have to install an entire new transmission. All help, ideas, suggestions are greatly appreciated.

[durrell]

You're sure it was gear oil and not motor oil? I had some sort of oil leak, changed my oil back to regular mineral oil (I was running synthetic) and tightened up my valve covers, and from what I've seen so far it appears to have gone away. When it was leaking a lot it would spray as far back as my gas tank skid and my rear differential would be splattered. I'd check there first. There's really no surefire way to check it since it's coming from the top (like mine). If it's gear oil I have no idea what to tell you..

Good luck and let us know what you find out..

[HKYStormFront]

if the trans is similar to the 5 spd used in the old HB's, i've switched a could upper seals where the shifter goes through the top and into the trans itself (at the pivot point) i forget the name of the actual part but when it goes, it makes a real mess, might be what caused you leak! take your shift boot off, then the rubber one below that and see what it looks like straight down (as if looking down into the trans) if it looks relatively clean, you're alright there and it's something else, if there's oil and crap everywhere, it's probably your problem. it's not a real expensive piece to buy, it is kind of a pain to install cause you have to reach down through the tiny whole for the shifter in the floorboard but it can be done

[houdini]

what side catalytic converter?

driver side....check power steering pump for leaks.

passenger side....check power steering fluid res for leaks.

both are usual suspects.

[jeopardy98]

I'll check under the shift boot and keep my fingers crossed that it's messy.

Houdini, it was the passenger side and I already checked the power steering fluid reservoir, I just forgot to put that in my original post. Thanks for the suggestion though.

I am positive it is gear oil, not regular engine oil. They have a completely different smell. Again, thanks for the reply and attempting to help me.

It sounds like I'm going to be wishing for a blown seal around my shift boot. I'll let you know what I find out. Also, if anyone else has any suggestions, fire away.

[durrell]

Ok, I figured that..just making sure..sounds like Pat's suggestion is going to be best..we'll keep our fingers crossed that it's as simple as that. (Well, not exactly simple..but at least not catastrophic transmission failure..lol)

[jeopardy98]

Okay now I'm having trouble getting the lower boot off. How do you get the 4wd shift knob off? My haynes manual only shows the 2wd version in the picture. I just unscrewed the main shift knob but the 4wd one won't budge.

It also shows the procedure for replacing the "shift shaft oil seal" which is where the linkage actually connects to the transfer case via a pinch bolt. There is apparently a small seal at that location that could leak. It is accessible from under the vehicle and looks like it might be a pretty good culprit for my problem. Does anyone know where I might find the replacement part other than calling the dealer? I've checked carparts.com etc.

[HKYStormFront]

for the record jeop, both the trucks i replaced that seal on were 2wd, it could be either one of those. i have no idea how to get that knob off tho can you get the console to pull up and see if it's somehow secured below the boot?

[durrell]

I'm pretty sure it's secured to the boot itself because the knob isn't threaded, is it? It has to be pushed down to engage the 4LO so I'm pretty sure it's attached somehow..

[silversuper]

thry giving it a good turn. my friends was a manual 4x4, nad i think his was a twist off.