Ok, after pulling the brand new trans pan off at least 10 times, replacing the gasket, re torqueing and re torqueing... This 300td still leaks from the pans around the bolt holes.

So, took it off and it seems to me that the outside metal of the pan in the center is actually contacting the bottom of the trans before the gasket can actually do it's job. At correct torque, I was unable to get a feeler gauge between the bottom of the trans at the top of these metal flanges (see pic).

I'm thinking I'll flapper wheel that bulge down a bit to get the gasket to seal.

Ideas?

Also, I was able to replace the bottom guide bushing w/o pulling the spring off. Yahoo!

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You might have the wrong filter fitted / or the filter could be fitted incorrectly. That might be stopping the pan from seating properly.

Look very carefully at the whole situation before you start removing metal from bits.

__________________
1992 W201 190E 1.8 171,000 km - Daily driver
1981 W123 300D ~ 100,000 miles / 160,000 km - project car stripped to the bone
1965 Land Rover Series 2a Station Wagon CIS recovery therapy!
1961 Volvo PV544 Bare metal rat rod-ish thing

I'm here to chat about cars and to help others - I'm not here "to always be right" like an internet warrior



Don't leave that there - I'll take it to bits!

Is that sealant around the trans pan gasket? I don't think that's necessary. Did you seal the gasket to the pan first? If so, that may be the problem.

Also, with a new pan (presumably unwarped) and not overtorquing anything it shouldn't leak. So have you considered if it's leaking above the gasket or dripping down from elsewhere?

Leaking above the gasket.

Yes, after countless attempts to get it to seal, I BlueRTV'd the gasket down to the pan, because it seems like the gasket wants to 'roll' into the pan. I also diegrinded (with the 3M gasket remover wheel) all the extra paint around the top of the brand new pan, thinking it was somehow causing the gasket to not fit correctly.

Yes, torque'd correctly, to inch lbs, barely hand tight.

After putting the pan on, filling the trans, it won't start leaking until I start the car. Then... drip drip drip from right above the center bolts. Right where that metal flange hits the bottom of the trans.

Also, Army, I looked at the clearance of the filter. It does not seem to be hitting or obstructing in any way.

So, after repeated R&R's on this trans pan, I finally clued in to what Yak was saying. I took 'above gasket' to mean btw tran and gasket, not that it might be leaking from somewhere completely dif than the pan.... Doah!

So, cleaned everything above the pan really well, filled it up, started it, and checked for the leak. The drip comes out right below that green bit in the pic, only when it's running. It seems that's where it's leaking from. You can just barely make out the wetness on the back part of the trans flange.

Solutions?

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Sorry I'm lost - which bit is leaking?

__________________
1992 W201 190E 1.8 171,000 km - Daily driver
1981 W123 300D ~ 100,000 miles / 160,000 km - project car stripped to the bone
1965 Land Rover Series 2a Station Wagon CIS recovery therapy!
1961 Volvo PV544 Bare metal rat rod-ish thing

I'm here to chat about cars and to help others - I'm not here "to always be right" like an internet warrior



Don't leave that there - I'll take it to bits!

Well, best I can tell, from under or behind that green part....

My blurry photo recognition skills are off. I'd call Phil or whunter and describe the problem. They've probably got a gasket or O-ring for that part.

I'm sorry to say I see no green part - that's my problem you see.

Which side of the picture below (of my 722.118 transmission) is your leak coming from?



Left hand side of the picture => rear end

Right hand side of the picture => front end

Bottom of picture => driver's side

__________________
1992 W201 190E 1.8 171,000 km - Daily driver
1981 W123 300D ~ 100,000 miles / 160,000 km - project car stripped to the bone
1965 Land Rover Series 2a Station Wagon CIS recovery therapy!
1961 Volvo PV544 Bare metal rat rod-ish thing

I'm here to chat about cars and to help others - I'm not here "to always be right" like an internet warrior



Don't leave that there - I'll take it to bits!