Oil leak from transfer case on tiptronic box.

So after thinking that it was my tiptronic sump gasket was leaking after changing the filter. Did the tiptronic sump again and still it drips. So I took a closer look and I think the leak is coming from the transfer case as the gearbox mount is definitely in need of replacement. Having read on the forums it looks like I need to do the following as it looks like no how to guide that I can see as Porsche replace the whole box when this happens. 1. drain the coolant to move the two coolant pipes out of the way. 2. I should then be able to access the transfer case and remove it to replace the gasket's without dropping the gearbox. 3. Do I have to watch out for any oil in the transfer case. 4. How do I remove the driveshaft that goes to the front? I have read that their are some seals that can also be replaced at the same time, anyone know the part numbers and where to get them from? Do I replace the whole gearbox mount or can I just get a bush? It looks like it has separated from the top completely. Many Thanks

There are x2 gaskets depending on whats leaking , i have no idear the part numbers im afraid , it all depends on where the leak is .. need a picture from the other side of where you have taken that one . The leak from the front one will show on the side closest to the tip sump , the leak from the rear casing and its normally the x4 bolts along the base that leak out past the threads .. silicone the bolts and its job done there. 1 of the bolts though is under the plate that the mount sits on so a bit of removeing bits to get at. If it is the gaskets then its a mission to do on a ramp let alone on the floor . Driveshaft and its x3 bolts , a bit of levering to move it back and off the flange then it will pull out of the diff .. its on splines. Not sure on the mount but i think its a complete unit . Rubber coolant pipes need changing. I was told you dont have to remove the fluid before doing it .. but i havent done a full strip yet and i think i would drain it reguardless .

Thanks Demort Unfortunately I have no option but to do this myself as the local specialist when I phoned them said we wouldn't know where to start. My other garage has had the mechanic I trust leave due to illness so only one other person I trust........me Have been considering getting a two post lift as I hate getting the car up onto axle stands http://www.ebay.co.uk/itm/2-POST-LI...776645&hash=item4ae93f22d8:g:BKsAAOxyXzxTIZ8x Thanks for the advice

Can't a gearbox specialist help :?: It's not a Porsche specific thing. They don't even make the boxes.

We do lots of these - £1395+Vat drive in drive out with warranty. No need to replace the gearbox. Ken

Amazing at how much needs to be taken off to get to this point.... Now ready to take the transfer box case off. Discovered that I need a new guibo as well. So full pictures of the bottom of the case and today it comes off. Any other seals or anything else while I'm this far in....

Ken at 9E is the guy for this work. Some of the gaskets are not even available and 9E makes then up. I have a friend who had the gearbox dropped twice for oil leak and then he spoke to Ken to have it sorted once and for all.

After playing it by ear I have removed the 16 hex head bolt holding the casing on.....should of listned to Dermot it does have fluid in it. Now draining before I go any further And best news of all a DIY https://rennlist.com/forums/997-forum/919387-transfer-case-leak-is-being-fixed.html Next installment tomorrow, tonight's task is to compile a list of parts I need to buy. Luckily I already have the gaskets required

Not wanting to hijack the thread, so a quick question to confirm whether the OP's problem is same as mine. I've had leaking oil issue for the last few years. First it was from all around the sump. After the seal was replaced as well as the connector, one side of the sump is now dry. However the area where there is the black arrow is pointing is still leaking/weeping. Did the OP have the same problem?

Also thought mine was a sump gasket leak, however I changed that and still had the leak. Doing further research I discovered that a common source a leak from that area is the transmission case as the gearbox mounts perish or just become worn which means the casing moves slightly and the gasket breaks. So I would suggest next step is to take off the under tray so you can look at the gearbox mount and the transfer casing. Look closely at the gearbox mount, mine had definitely had it......

For the black arrow and yes its the same area as the OP,s leak . This can be either the main gaskets or x4 of the rear bolts leaking through the threads , whilst this is technically the rear of the 2 gaskets leaking you can repair it just by removeing and putting silicone on the bolts then refitting . x1 of these bolts is under the plate which is in turn under the gearbox mount. Easy enought to check as when you remove the bolts they will be covered in oil .

Hats of to those garages such as nineexcellence.com who do this fix. The amount of time involved is immense but this is the first time I have taken something like this apart.....found the cause though. Considering the parts price to repair at this stage is £150.00 inc Vat for the replacement gaskets £180.00 inc Vat for the new gearbox mount £100.00 inc Vat for the new flex disc - not sure if this would be included if the garage was to do it. So today I got the second casing off and looks like gasket and I am going to replace the 'o' rings on the oil tube as I'm their and it looks like that might be another source of oil leakage. Looks like the 'o' rings i need are 16 x 2 Nitrile for the oil tube and 1 other which is 30 x 2 Nitrile which is for a seal on the first case. So once I have those I can start putting it back together......

Yes and yes!! I'll need to get the gearbox mount checked properly i.e. on a ramp, not on my back with 20mm clearance. If only I have some kind of proper lift/ramp ... Oil is deposited around the bolts on the side of the black arrow - OPC thought that the sump has warped causing the leak. I can't believe that my long-running leaking saga can be addressed by putting silicone on the bolt (and replacing the mount at the same time). Thanks heaps gents!!

Out of interest does anyone know the torque for the bolts to put the transfer case back together. I have found that someone has mentioned 19lb sq ft for the casing and 38lb sq ft for the hex bolts holding the gears in. Thanks in advance. Shaun

Today was giddy excitement day..... Transfer case back together, coolant pipes going on, refill coolant, fill tiptronic atf fluid.....nervous excitement that it might be back on the road today. Could feel the drive getting closer, been a while, cab roof issues, transmission leak, water pump and finally, family commitments and holiday, this oil leak. Must be three months in total. Water topped up, final fill of the atf fluid, take it off axle stands and YES out on the road with the roof down. Get back check underneath and no oil dripping....an epic journey to fix now I know why it costs what it does to get done. A lot of effort but a job well done. When I find the time I will right a how to...from what I have learnt and found on the net.