Automatic pan leaks

[scooby split]

Hi folks I've tried sealing my Type 3 Automatic pan 6 or 7 times half of them with the cork gasket half of them with just the permatex Gray Auto sealant and once with a combination of the two but after a short while driving it starts leaking again the pan is fairly straight I'm sure it's ok , could the gear box be over pressurising is there a relief valve that could be sticking or is there a way to reduce the internal pressure ?
I know it's an odd one and I always seem to have the problems no one else has ever had but any advice would be most welcome as its costing a fortune in sealer and gaskets

Cheers Phil

[KTPhil]

Are you sure it's from the oil pan, and not the governor or the kickdown switch plug?

I think there is a loose metal cap over a vent on the top.
You can see the cap on the final drive side of the mated transaxle.

Also shown here:

_________________
Current Fleet:
- '71 Fastback
- '69 Westfalia
Retired:
- '67 Beetle
- '65 Beetle (x2)
- '65 Bus
- '71 Squareback

[Bobnotch]

I'd also check the final drive gear oil level. The key here is to make sure NO ATF is getting in it, mixing with the gear oil, as that can damage the final drive gears.
_________________
Bob 65 Notch S with Sunroof
71 Notch ...aka Krunchy; build pics here;
http://www.thesamba.com/vw/forum/viewtopic.php?t=249390 -been busy working
64 T-34 Ghia...aka Wolfie, under construction... http://www.thesamba.com/vw/forum/viewtopic.php?t=412120

[scooby split]

Hi I'm pretty sure it's the oil pan leaking because it doesn't leak after I've resealed it until I go for a drive or two, then it doesn't stop leaking until the ATF has all spilt out, I would have thought if it was leaking higher up on the box it would only leak out when the engine was running ?
as it is ATF leaks from the bottom of the box when stood and unused
but I will have a closer inspection when I get a chance I am loathed to take the box out as it's in my splitscreen van and theirs very little room to get the spanners to it

So if any one has any suggestions for sealants or a possible causes for over pressurising
or if any one else has suffered with the same problem just let me know how I might fix it please .

Cheers phil

[KTPhil]

You have a full auto trans in a split screen bus?! DO tell (when you get a chance)!

I have discovered bent covers (auto pan, valve covers) by fitting them "loose finger tight" without a gasket, and trying to rock it. I have even smeared grease very thinly and smoothly on one side, and then inspected it to see if it made or failed to make contact based on the "smear." That reveals slight warping that isn't otherwise very apparent. Then going after the defects with a vice/anvil, ball peen or metal hammer, body dolly, etc. Mind the edges, which can make an otherwise good gasket distort, even if the sealing faces are right.

Do mind the potential for mixing ATF and gear oil from a bad seal between the two parts of the transaxle. The mixed oil will ruin one side or the other without much warning. Replacing the seal is a PITA but doesn't require the precision tools and jigs that an actual rebuild does.
_________________
Current Fleet:
- '71 Fastback
- '69 Westfalia
Retired:
- '67 Beetle
- '65 Beetle (x2)
- '65 Bus
- '71 Squareback

[Bobnotch]

[scooby split]

Hi thanks for everyone's input I will check all the above suggestions and if im no wiser I will try and do the pan seal again, I have another pan on a parts gear box but honestly it doesn't look any straighter I have previously checked them with a streight edge and hammered the high spots down to help it seal better I might stick the cork gasket to the pan and leave it to dry then do the same and stick it to the box finger tight before i finally torque it up and see how long that lasts .

Thanks again for all the suggestions and if any one can suggest any other things that could cause this issue then please give me a shout.

Cheers phil

[scooby split]

Hi kTPhil yes I have an auto split that I've owned over 20 years now, my dad and me worked on it and did the conversion to auto as I have a disability and the powers that be say Im only allowed to drive automatics hence the conversion, it had an air cooled 1600 but it was way underpowered for the auto box and had to be driven flat out all the time to keep up with other manual splits when in convoy, later on it got a 2lt Subaru engine fitted which suited the automatic box much better because being driven flat out the kick down was always kicking in and reving the nuts of the engine now that never happens the peadle never needs to be pushed that far down any more, I had the gear box rebuilt but once installed it would slip slightly in 2nd so I sent it back and they installed extra clutches in the clutch pack but after installing it again it wasn't much better but as you know 2nd gear only runs from about 15 mph to 30 mph so I just had to put up with that it never got any worse and it been fine up until the last couple of years until the leaking pan, it's a shame to have it and not be able to drive it so hopefully we can figure it out .
Here's the bus I hope you like it cheers Phil

[KTPhil]

Amazing Bus in every respect! Wow!

Once you get past your immediate leak issues, please share more photos of the install. Non-trivial, to say the least, and it looks so clean.

Glad you get to keep on Busing with this unicorn!
_________________
Current Fleet:
- '71 Fastback
- '69 Westfalia
Retired:
- '67 Beetle
- '65 Beetle (x2)
- '65 Bus
- '71 Squareback