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Old 10-22-2011, 10:35 AM   #11 (permalink)
Bex
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One of my deepest regrets is that there is no Jiffylube in Ireland......
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Old 10-23-2011, 10:44 AM   #12 (permalink)
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While I appreciate all the info, we seem to be getting lost in the trees here. I'm 67 years old and laying on the ground pulling 75 ft-lbs on a torque wrench during the installation of a receiver hitch is about the limit of my capability. The leak is at the rear of the transmission and it's not the gasket. So my original question is about the difficulty of removing the transfer case. If it's pretty tough, then I'll be taking the Sidekick to the shop. Right now I can't get the thing inspected because of the fluid getting on the catalytic converter and smoking. I'm not trying to re-invent the wheel here, I'm just trying to get a little friendly advice.
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Old 10-24-2011, 07:04 AM   #13 (permalink)
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Hereís where mine was leaking Ė like yours, right on the cat.



Blue connector for the TCC lock up circuit. It can be got to by dropping the tranny pan, disconnecting the wires at the bottom, then pushing the connector up through the hole. You should then be able to pull the connector through the space between the tranny and hump. Inspect the rubber O-ring, mine was cracked. I wasnít able to find a replacement O-ring so I just bought a whole new connector. Replace in reverse order using a string through the loop in the bottom of the connector to pull down and seat it. Hope this is your problem because itís a relatively easy fix.
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1991 Geo Tracker. Hardtop Made in Canada (per VIN)
Engine: 1.6L, 8 valve
Transmission: 3L30, 3 Speed
Transfer Case: Stock (Unk type)
Tires: 255/70R 15 (29x10x15 approx) on no lift.
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Old 10-24-2011, 08:06 AM   #14 (permalink)
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the tranny has lots of seals
keep an open mind on which one cna fail.
Patience and looking idling will find it.
if not, then drive around the block , park ,look and repeat.
it will leak and you will find it
and the UV dye does help greatly and cheap compared to a new tranny.

do you need a full list off all seals on the tranny to find it.? id think not, if you just look
and catch it.
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Old 10-24-2011, 10:40 AM   #15 (permalink)
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o2bgpn - glad to see there's at least a possibility something besides the rear seal could cause the fluid to show up where I'm seeing it. I've got the whole thing up on ramps and stands so I've got some working room and after lunch I'll get out there and scrub things down better and see if I can trace the path of the fluid. Even though it's setting level now I'm still getting some leakage.
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Old 10-25-2011, 10:29 AM   #16 (permalink)
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Update - I cleaned everything up as best I could with a Simple Green solution and scrub brushes. Then sprayed all down with brake cleaner. o2bgn - thanks to your pic, I could get a sight line on that TCC lockup connector from the engine side. It was completely crudded up. After all dried out I stuffed some paper towels in various locations and, so far, the only pink fluid I'm getting is from that location. I ran it for a minute and after sitting overnight I'll check again. I'm pulling the shifters to see if I can get a sight line through the transmission tunnel holes, but it seems unlikely.
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Old 10-26-2011, 07:45 AM   #17 (permalink)
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I don't remember an access cover under the transmission shifter, since it is cable operated. The only access cover would be via the transfer case shifter, but Iím pretty sure that is too far back to be of any use. The only way I could see the blue connector was using a flashlight to look from the front of the engine, back past the exhaust, and between the tranny and hump. And then, since Iím old and my eye sight sucks, I couldnít make out anything useful. I ended up pulling the transmission (as seen in the picture) just to be sure it wasnít something else. But if you donít feel comfortable pulling the transmission I would change the connector just because itís about the only thing you can do without pulling the tranny Ė and itís only $5.

Quick question, is your tranny fluid level correct? Iím just asking because when mine was at the proper level it leaked all the time. Especially when the engine was off and all the tranny fluid flowed back into the pan.
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1991 Geo Tracker. Hardtop Made in Canada (per VIN)
Engine: 1.6L, 8 valve
Transmission: 3L30, 3 Speed
Transfer Case: Stock (Unk type)
Tires: 255/70R 15 (29x10x15 approx) on no lift.
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Old 10-26-2011, 08:25 AM   #18 (permalink)
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my over 60 eyes, , i go to the "Dollar Store" ( i have their stock too) and buy all 1x to 3.5x reading glasses.
and put them in my tool box, now i can see at any range. YMMV.

btw all the seals are sold. see ID below( all Suz ID)
leaks: now we do the list. 3L30 box.
  1. front cover inspection cover (bellhousing) below dead center of TC, is there ATF leaking here?
  2. the Transfer case has an vent in the front dry box. see photo below.
  3. the xfr case TO the 3sp case. and is dry,
  4. see a slit (slot) at the SPLIT? make it clean with a knife. look for test drain plug.?
  5. does it drip ATF? if yes, rear seal 3sp is shot, (or worse) iD #14 (GL4 xfr case seal fail, ATF , 3sp seal fail)
  6. worse is bad bushing on 3sp tail shaft that beat out a good seal, most seals fail because they are victims.
  7. gear shift shaft o-rings leak. Id 3 page 63 (right side of tranny under PRN switcH)
  8. TCC connector lower left 0ring leaks.ID 14 (per poster here, a ten cent seal)
  9. pan gasket leaks?
  10. pan drain (if fitted) leaks.?
  11. rear gasket to transfer case adapter cracked.
  12. vac mod o-ring seal #27 bad
  13. TV "kick-down" detent seal #21 bad
  14. the 2 right side oil lines to RAD can leak, end to end.
  15. the top of tranny has a vent, if blocked the tranny will leak every where. ( make sure the vent is clear)
  16. tranny dip tube base o-ring leaks, id 19
  17. the tranny vac mod diagram is cracked inside AND the hose to it, is cracked, and now leaks ATF. (so common, its a crime)
  18. left side pump test port plug leaking.


tell me , did i NAIL it.
every single leak point.
if the inspection cover leaks, then it expands..... tranny out......

btw , not 2 posts ever , for 3L30 had the same leak for the same reason. IIRC. (4 years and lots of email)
so guessing is not going to work. its random.
requiring mech to actually find it.
but Vac mod leak is really not a leak ,its a total failure. and is common.
i think we have 1 each, detent and 1 shift-shaft ever.
the other high fail is poor fitting pan gasket (poor service) " someone broke it"

the transfer case has nothing to do with this.
it uses GL4 lube not ATF
so looking there is a waste of time. for this squawk.
the center case does have a vent on the bottom,
next is a photo of that.


on some years, here is 91
the center dry case looks like this
there is a vent and a drain plug.
that drain plug is just for testing for leaks. after all ATF or GL4 can leak from either seal front or rear to dry case.
see vent here. look careful see drain plug , just below it. ?
my SUZ EPC shows the dry case is the same, 3sp,4sp,5sp, and is married to the transfer case; the tranny uses an adapter to fit 1 dry case design.
4wd not 2wd, (2wd is diffr)

how are are those Apples

Last edited by fix-kick; 10-26-2011 at 08:51 AM.
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Old 10-26-2011, 08:51 AM   #19 (permalink)
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summary
dont jump to conclusions
some problems are easy and cheap to fix.

as they say, Gather Evidence first . "facts" and follow them to TRUTH.

yes, i too ,just hate leaks.
the are sometimes a warning to more serious issues, coming up.
eg: bearing failure, and seal is beat to death.

Last edited by fix-kick; 10-26-2011 at 08:54 AM.
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Old 10-26-2011, 03:00 PM   #20 (permalink)
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Checked the fluid cold, haven't run engine since yesterday. It's about 1/4 inch above the top hot mark.
Seeing the sensor from the backside through the transmission shifter hole was about the limit of that sightline, but wasn't particularly helpful. Will put the console back together tomorrow.
Tried to check with Southwest Suzuki about the o-ring but couldn't get it to come up on their website. Sent them an email.
There was a little trans fluid on the bottom passenger side of the bell housing. Dried it off to see if it reappears. It might have blown there from the torque converter inspection hole when I ran the engine for a few moments yesterday.
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