2005 P1 S40, 6-speed manual trans AWD:

I just replaced the right side axle and trans fluid and noticed an extra pool of fresh (expensive) transmission oil on the garage floor. This is not the stuff that leaked out when removing the axle nor is it the overflow from filling the trans. Much cleaning and inspection ensued leading me to the determination that the new leak is coming from between the trans and the angle gear (AG) housing.

Now my research leads me to believe that I damaged the seal that the axle goes through at the exit of the transaxle (and probably the AG output too).

This is where things get fuzzy and I come to BB for advice: I don't understand the interface between the trans, AG and front drive axle. What parts should I be ordering to fix the leak and what else should I be replacing while I have the axle and AG out?

I'm not finding much out on those internets about how the trans/AG/axle all interface. here's what I *know* from observation: The axle comes out of the trans, through the AG and on its merry way to the CVs and hub. It does not transmit any power to the AG, merely passes through. The axle has sealing surfaces for the exit of the trans and exit of the AG, but not the input to the angle gear.

Here it gets fuzzy. The angle gear gets it's motive force from an interface with the trans via a female splined sleeve. One that tends to strip out and require replacement. This sleeve has an oil seal both on the OD and the ID. OD for the sleeve, ID for the axle that rides inside it. But then the angle gear input must also have a seal, right?

In any case, I'm having trouble determining which part numbers I need. Pretty sure 9143885 is for the axle seal on the transmission (inside the sleeve) and 30681339 for the angle gear FR axle output. Angle gear oil should be refreshed of course. What else? I don't understand what seals the input into the angle gear, especially since there isn't a machined surface on the axle to mate to.

Thanks for reading. I appreciate any insight I can gather. I could go in there and pull it all apart, but, as always, garage time is short and I don't want to take the car out of service.

An update:

After a few days of parking in the street, the little oil spots in the pavement went away.

Over the weekend I jacked the left side of the car up (placing the fill plug higher than I had it before) and was able to just barely fill the trans with the last of the second quart of Redline MTL. Cleaned the area of any excess oil, then placed a clean piece of Ikea grade cardboard under the car. No drips.

I conclude that removing the drive axle allowed more oil than I thought to escape and that the inaccessible void between the trans and angle gear holds a decent amount of oil.

Other notable notes:
- Redline MTL appears to be fine substitute for the OEM fluid. I notice no difference in performance or feel (the badly worn CV joint and broken engine mount on the other hand, what a difference!)

- I also installed a CURT 11438 trailer hitch yesterday. Happy with the finish on it, not so much the fit. It's about 1/4" too wide. The large diameter holes in the hitch allow it fit just fine but it interfered with the exhaust brackets. I had to drill the bracket holes larger and shift the bracket outboard about 1/4". Makes the rubber hanger to the muffler hang a bit crooked but should be ok.

Sorry I was gone. Glad to hear that the 'leak' is resolved.

The angle gear is in constant motion when moving, driven by the transmission output shaft. The front axles have nothing to do with the AG, the axles are driven by the tranny. Now, if either one of the front axles comes loose, the differential will cause the car to stop moving, completely.
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Keeping it running is better than buying new

Your absence did not go unnoticed!
Nice to see you back; I hope all is well in your world.

While I did not enjoy all the crawling, reaching, cleaning and prodding I did while lying on a cold garage floor, it was nice to learn about the state of the car and gain a bit of an education on how it functions.

First snow of the season here last night. I was finally able to test out the AWD system on my drive home after a long day at work. I was pleasantly surprised how seamlessly the system engaged. This is my first AWD car; the difference in handling is interesting. I'd like to get a good set of snow tires on it to really see how it performs. I think I'd like it even more than a RWD brick with snows and a full tank of gas. Wheeeee!