I'm looking for help with my oil separator/breather box, which appears to be leaking oil from the bottom, where it seals on the block. I posted about this 6 weeks ago, and since that time replaced the o-ring, then the box itself, with no improvement.

The top and forward edge of the box are clean and dry...


but the rear portions and bottom are wet with oil:


That's a brand-new box, installed 2 weeks/1000 miles ago... but it looked like that after driving just a couple hundred miles.

When the box is removed, the areas below, behind and to the sides are wet with oil:


I lost about 1/2 quart of oil over an 800-mile highway trip. The oil is going back along the transmission and getting on the exhaust at the trans-downpipe brace... I can smell it burning on the exhaust.

Today before I put it all back together, I made sure the oil return pipe was clear, and put a little bead of RTV on the bottom of the box around the o-ring and return pipe seal, but after driving 20 miles I had the same leak again.

The return pipe seems snug, but maybe it's not making a leak-proof seal with the block and/or box? I'm stumped.

- Brian '93 945T