GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2005 🢒 Sunfire 🢒 Transmission/Transaxle 🢒 Manual Transmission - Getrag 5 Speed 🢒 Transmission Fluid Leak Diagnosis

Diagnostic Aids

Using the incorrect type of transaxle fluid may affect the sealing ability of the seals. Ensure the use of the correct type of transaxle fluid. The incorrect type of sealer may not be compatible with the transaxle fluid or may not have the correct characteristics for sealing the affected components. Ensure the use of the correct type of sealers. Refer to Sealers, Adhesives, and Lubricants in the Transmission Unit Repair Manual.

Test Description

The number below refers to the step number on the diagnostic table.

  1. Use an approved method to clean the transaxle to ensure the leak location is correctly identified. If using a powder method or dye method, ensure the products are compatible with the transaxle fluid.

Step

Action

Yes

No

DEFINITION: Visible sign of the transaxle fluid leaking from the transaxle.

1

Did you review the Symptoms - Manual Transmission and perform the necessary inspections?

Go to Step 2

Go to Symptoms - Manual Transmission

2
  1. Inspect for the transaxle fluid level higher than the recommended level. Refer to Transmission Fluid Check .
  2. Adjust the transaxle level if incorrect.

Was the transaxle fluid level too high?

Go to Step 24

Go to Step 3

3

Inspect the transaxle vent for a blockage.

Is the transaxle vent blocked?

Go to Step 4

Go to Step 5

4

Repair or replace the transaxle vent.

Did you find and repair the condition?

Go to Step 24

Go to Step 5

5

Verify the location of the leak.

  1. Clean the transaxle assembly.
  2. Operate the vehicle for 24 km (15 mi), or until normal operating temperatures are reached.
  3. Visual inspect or use the powder method or dye and black light method to locate the leak.

Is the leak occurring at the drain or fill plug?

Go to Step 6

Go to Step 7

6

Replace the drain or fill plug. Refer to Transmission Fluid Check .

Did you find and repair the condition?

Go to Step 24

Go to Diagnostic Aids

7

Is the leak at the transaxle output shaft seal?

Go to Step 8

Go to Step 9

8

Remove the output shaft seal and inspect for the following. Refer to Axle Shaft Oil Seal Replacement .

    • Damaged or worn seal
    • Damaged seal bore
    • Improper installation
    • Cracks in the component
    • Loose or worn bearing causing excessive seal wear

Did you find and repair the condition?

Go to Step 24

Go to Diagnostic Aids

9

Is the leak at the shift lever area?

Go to Step 10

Go to Step 11

10
  1. Inspect the shift control lever lower boot for damage.
  2. Inspect for loose shift control lever mounting bolts.
  3. Remove the shift control lever. Refer to Transmission Control Replacement .
  4. Replace the shift control lever lower boot if damaged.
  5. Inspect the shift control lever sealing surfaces for scratched, nicked or damaged.

Did you find and repair the condition?

Go to Step 24

Go to Diagnostic Aids

11

Is the leak at the front of the transaxle?

Go to Step 12

Go to Step 15

12
  1. Remove the transaxle. Refer to Transmission Replacement .
  2. Inspect the input shaft retainer for leaking.
  3. Remove the input shaft bearing retainer. Refer to Axle Shaft Oil Seal Replacement . Replace the seal.

Did you find and repair the condition?

Go to Step 24

Go to Step 13

13
  1. Inspect for the leak at the input shaft seal.
  2. Inspect for the following if the input shaft seal is leaking:
    3. • Damaged or worn seal
    • Damaged seal bore
    • Improper installation
    • Cracks in the component
    • Input shaft sealing surface is scratched, nicked, damaged or worn
    • Loose or worn bearing causing excessive seal wear
  3. Replace the input shaft seal if leaking. Refer to Axle Shaft Oil Seal Replacement .

Did you find and repair the condition?

Go to Step 24

Go to Step 14

14
  1. Inspect the case for cracks or porosity.
  2. Replace the transaxle case or clutch housing if it is faulty. Refer to Transmission Case Disassemble in the Transmission Unit Repair Manual.

Did you find and repair the condition?

Go to Step 24

Go to Diagnostic Aids

15

Is the leak at the vehicle speed sensor (VSS)?

Go to Step 16

Go to Step 17

16
  1. Remove the VSS. Refer to Vehicle Speed Sensor Replacement .
  2. Inspect for the following:
    3. • Cut or damaged O-ring seal
    • VSS over-tightened causing deformation in the VSS
    • VSS bore scratched or damaged

Did you find and repair the condition?

Go to Step 24

Go to Step 1

17

Is the leak at the backup light switch?

Go to Step 18

Go to Step 20

18
  1. Remove the backup light switch. Refer to Backup Lamp Switch Replacement .
  2. Inspect for the following:
    3. • Cross threaded or damaged threads
    • Insufficient sealant
    • Leaking switch
    • Improper installation

Did you find and repair the condition?

Go to Step 24

Go to Step 1

19
  1. Remove the shift shaft detent sleeve. Refer to Transmission Case Disassemble and Transmission Case Assemble in the Transmission Unit Repair Manual.
  2. Inspect for the following:
    3. • Cross threaded or damaged threads
    • Insufficient sealant
    • Cracked sleeve or case
    • Improper installation

Did you find and repair the condition?

Go to Step 24

Go to Step 1

20

Is the leak at the sealing flanges of the transaxle case?

Go to Step 21

Go to Step 22

21
  1. Remove the transaxle. Refer to Transmission Replacement .
  2. Disassemble the transaxle. Refer to Transmission Case Disassemble in the Transmission Unit Repair Manual.
  3. Inspect the sealing surfaces. Refer to Clutch and Differential Housing Cleaning and Inspection in the Transmission Unit Repair Manual.

Did you find and repair the condition?

Go to Step 24

Go to Step 22

22

Is the leak coming from a crack or porosity in the transaxle case?

Go to Step 23

Go to Diagnostic Aids

23
  1. Remove the transaxle. Refer to Transmission Replacement .
  2. Disassemble the transaxle. Refer to Transmission Case Disassemble in the Transmission Unit Repair Manual.
  3. Replace the faulty transaxle case or clutch housing. Refer to Transmission Case Assemble in the Transmission Unit Repair Manual.

Did you find and repair the condition?

Go to Step 24

Go to Diagnostic Aids

24

Operate the system in order to verify the repair.

Did you correct the condition?

System OK

Go to Step 1