Oil pan Gasket replace on AWD TSi...HOW TO?

TGPilot · 05-21-2005

Hey guys,

On my 94 TSi I have a signifigant oil leak from what appears to be the oil pan. It is moist up the rear of the block...but very wet on the pan from the mating surface down. The timing belt and parts under the cover are not wet so I am assuming that the front seal is not bad. I put a flex scope in on the flywheel side and it is dry in there. Front of the engine is DRY as a bone so I am pretty sure the pan gasket will solve the leak.

My question is this...HOW do I get it off with a transfer case? Do I pull the entire prop shaft and then the transfer case from the tranny? or do I just unbolt the transfer case and swing it out of the way?

What is the easiest way? Do I need or is it recommended to do any additional seals while I have the transfer case off? Step by step would be nice...but major component removal in order is plenty for me!

Thanks guys!

-Kenny

Alpine TSi · 05-21-2005

Just drop the t-case with the shaft still in it, it will move enough to let you put it on the floor without hurting anything. Then make sure you get the two short bolts that hold the pan on back where they came from, or you will score the timing belt and make it weaker. Don't use a gasket either, just use some good RTV.

TGPilot · 05-21-2005

I was hoping I could just move it asside! Any recommendations for RTV? I normally use Permatex Ultra Black (598B). But if you guys know of something better I am up for suggestions!

-Kenny

Raptor · 05-21-2005

You have to of course drop the down pipe as well, I usually use either the ultra grey or black, either will work fine, just make sure it stays to the outside of the rail etc, you don't want any excess to squeeze inside the pan. I usually spread it out so I have more control of where it ends up and how even the contact area is.

**Goat Blower** · 05-21-2005

To be specific, the short oil pan bolt goes into the front cover between the crank sprocket and the oil pump sprocket. The other short bolt should go directly under the oil pump sprocket but doesn't really matter, it wouldn't make contact with the belt.

TGPilot · 05-21-2005

In order to drop the pan it is just the bolts that run around the bottom of the pan right? Plus getting the T-case and downpipe out of the way.

Sorry if I sound confused...I was in 95* blazing Colorado sun all day and my brain no worky tonight!!

TGPilot · 05-22-2005

Final question. What fluids should I use to replace in the T-case and the Tranny while I am under there? I do not mind spending a few extra bucks for quality fluids if it will "Help" the lifespan of the gear boxes...

Thanks-Kenny

EclipseGST · 05-22-2005

BG Synchroshift, GM Synchromesh, Royal Purple, Redline, etc... All will work fine. 75w-90 is most commonly used. Everyone has their opinions on whats best.

EDIT: Dont use GL-5 in the tranny. It is corrosive to the synchros.

TGPilot · 05-22-2005

I have GM Synchromesh in the gearbox now. Just seemed REALLY thin while at temperature when I checked the level. The tranny does not scratch or grind in any gear while hitting it hard or easy driving. synchromesh just seemed a bit thin to me...