Manual Conversion, Intermediate Driveshaft Not Sealing Options

[jimay3672]

Hi everyone, I recently did a manual conversion on my 3.0L TF Magna Altera.
During the conversion I changed over the intermediate driveshaft (driver side half shaft) which was slighly shorter than the auto one.
After doing the conversion and driving around for a bit I noticed a leak on the diff seal so I replaced the seal.
I'm still getting the leak.

I'm wondering if for some reason the intermediate shaft I put on is too short and I need to put the auto one back.
My reason for thinking this is that the metal dust seal (metal ring) on the drive shaft does not go over the lip of the seal once all bolted in and sits about 0.5-1mm out from the lip of the seal which is where the oil is leaking from.

I have two questions.

Do the diff seals need to be pushed all the way in?
Is the drive shaft dust cover meant to go over the lip of the seal? if not why is it even there?

At this point I'm going to pull the drive shaft off again (take 3) and see how the old driveshaft lines up, if the dust cover goes over the seal and it doesn't seem to be hitting anything in the box then I'll swap it over..

Has anyone else who did a manual conversion had this problem?

Thanks.

[chain rattle]

a guess

does the intrim shaft into the diff have a circlip

if so the circlip may need to be replaced

on most gearboxes the seal should be flush with the box

you may have damaged the seal when fitting they are tricky to do

[jimay3672]

a guess

does the intrim shaft into the diff have a circlip

if so the circlip may need to be replaced

on most gearboxes the seal should be flush with the box

you may have damaged the seal when fitting they are tricky to do

No, no circlip nor on the old shaft.
I pressed the seal in again yesterday with a prybar (crude but the only way I could get leverage with the location)
Today it doesn't appear to be leaking.. (I wish I knew that before undoing the wheel hub nut)
I'll keep my eye on it for the rest of the day while it's on stands and see if I get anymore leaks..

I am concerned about the .5mm gap between the seal and the metal dust cap on the end of the driveshaft though, surely that's not normal?

[KiT TeUnG 2549]

the output shaft dust seal seats nearly flush against the seal area. It is easy to look onto the shaft and see the area where the ridge of the shaft rides. It goes in pretty far into the transmission. The difference in the shafts is abs/traction equipped and non , and models with ride control etc. But emerly abs im suppossing in this case.

Are yu getting a seal for the output shaft for the manual transmission? Is the shorter output shaft for the manual or automatic? Also there is a difference in the otput shaft seal frum left to right in my catalog. Also yu need to be carefull no to dislodge the circular spring that adds a little compression on the lip of the seal. If yu install it crooked or uneven or accidentally the wrung way it will leak. Also if yur gearbox is overly full it will cxause a leak also.

[jimay3672]

the output shaft dust seal seats nearly flush against the seal area. It is easy to look onto the shaft and see the area where the ridge of the shaft rides. It goes in pretty far into the transmission. The difference in the shafts is abs/traction equipped and non , and models with ride control etc. But emerly abs im suppossing in this case.

Are yu getting a seal for the output shaft for the manual transmission? Is the shorter output shaft for the manual or automatic? Also there is a difference in the otput shaft seal frum left to right in my catalog. Also yu need to be carefull no to dislodge the circular spring that adds a little compression on the lip of the seal. If yu install it crooked or uneven or accidentally the wrung way it will leak. Also if yur gearbox is overly full it will cxause a leak also.

So is the dust seal meant to sit over the flared lip or as you said against it? does the dust seal play a part in the oil sealing at all?
The manual shaft is shorter than the auto by about 8mm I tried the auto shaft today but it's too long.
My car is non abs, I'm not sure if the car the parts come from was abs or not, apart from the length difference the shafts are exactly the same.

Hmm, Mitsubishi looked in their parts catalouge and just sold me two identical seals which they said were the same for manual and auto and both sides.
The circular spring didn't come off, but with how far the driveshaft goes in the spring is only just over the part of the shaft it's meant to seal on..
I considered pressure in the gearbox from too much oil.. I filled it on level ground and waited until oil stopped coming out of the fill hole before plugging it.

Hmm, I may need to just take the car in to mitsubishi...

[KiT TeUnG 2549]

I do not think yu need to take it in to mitsubishi , i think yur on the right path. The seal should seat flush with the housing and so should the dust cover. Before installing teh seal , slide it over the intermediate shaft and see how well it fits before installing it on the transmission. It should have a pretty good fit , not to tight and not to loose. There is a thrust bushing in the transmission behind where the seal fits , If this bushing has been damaged , maybe by the shaft during instillation , this will also cause a leak , as for this bushing keeps most of the oil and pressure frum , getting past and leaking past and allowing more pressure at the seal than it is made to withstand .

[jimay3672]

I do not think yu need to take it in to mitsubishi , i think yur on the right path. The seal should seat flush with the housing and so should the dust cover. Before installing teh seal , slide it over the intermediate shaft and see how well it fits before installing it on the transmission. It should have a pretty good fit , not to tight and not to loose. There is a thrust bushing in the transmission behind where the seal fits , If this bushing has been damaged , maybe by the shaft during instillation , this will also cause a leak , as for this bushing keeps most of the oil and pressure frum , getting past and leaking past and allowing more pressure at the seal than it is made to withstand .

Here is a picture, sorry about the quality, it's not to scale either
This was taken with drive shaft fully attached and bolted in.
The dust seal lip isn't making contact with the seal at all..

Maybe I've been sent the wrong driveshaft with the conversion kit.?

My car is/was a TF V6 auto.
The manual box and shafts apparently came out of a V6 TE
If I try putting in the auto intermediate shaft it goes in and covers the seal.. but stops short of being able to bolt it to the engine by about 4 - 5mm (won't go any further into box)
Could there be damage to the end of the intermediate shaft where the CV attaches that has caused it to be shorter? like a spacer missing or something? The shaft came in one peice (drive shaft attached to intermediate shaft)

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 100_0417.jpg ( 195.2K ) Number of downloads: 12
 100_0415.jpg ( 176.18K ) Number of downloads: 12

 

[chain rattle]

good to have pictures thanks

the shafts should be the same for that model


looks fine by the pics

as long as it doesnt leak youve done a good job (IMG:style_emoticons/default/nahrung034.gif)

Attached File(s)

 1.JPG ( 12.41K ) Number of downloads: 7
 2.JPG ( 14.04K ) Number of downloads: 7

 

[jimay3672]

good to have pictures thanks



the shafts should be the same for that model

dont know why you have a leak

maybe a faulty seal ??? who knows

It's a brand new seal.
brand new seal number 2 lol..
Hmmm.. I don't think I can be bothered pulling everything apart for the sixth time to try reseating the seal so might just have to bite the bullet and get someone with the right tools to do it..

Thanks (IMG:style_emoticons/default/smile.gif)

[chain rattle]

good to have pictures thanks

the shafts should be the same for that model


looks fine by the pics

as long as it doesnt leak youve done a good job (IMG:style_emoticons/default/nahrung034.gif)

you were too fast for me I edited my post (IMG:style_emoticons/default/blush-anim-cl.gif)

[KiT TeUnG 2549]

Ill say like this , its all about wut company makes the seals and the quality , which is why i say , before installing the seal , slide it on the end of the shaft that is going into the transmission and check the feel of the seal on the shaft. This way can determine wut the seal will fit like when its installed on the car. Ive mentioned many things above about tryin to remedy it. It may be simpler than yu think.

[jimay3672]

Ill say like this , its all about wut company makes the seals and the quality , which is why i say , before installing the seal , slide it on the end of the shaft that is going into the transmission and check the feel of the seal on the shaft. This way can determine wut the seal will fit like when its installed on the car. Ive mentioned many things above about tryin to remedy it. It may be simpler than yu think.

Thanks, if the seals look fine and it's only leaking when I drive it at freeway speeds then I've probably overfilled the gearbox fluid which is causing pressure as you said and forcing the fluid to leak, or I've not put it in perfectly straight.

When I've put the seal over the shaft off the car it seems to fit nice and snugg.
The seals are Mitsubishi MD755904

Will see how it all goes over the next week or so before pulling it apart again.

Thanks for everyone's help ! (IMG:style_emoticons/default/smile.gif)

[TechJunkie]

When i had my TE V6 Altera,i've received lots of help from this forum,lots of knowladge there,u might get a better help from them.Good luck.

http://www.aussiemagna.com/forums/forumdisplay.php?f=10