2011 Rogue Transfer Case Leak. Please help!

[unistang]

All,

Just did the transfer case drain and refill last night and I have a leak somewhere that I can't pinpoint. This is my second time doing this on this car. The first time I had no issues, even reused the plug gaskets. This time not so much. The first time I tried reusing the gaskets again and I saw a leak so I headed to Nissan, bought two new crush washers, removed the old and in with the new. Everytime I drive the car I can smell oil had dropped on the exhaust when I pull into the garage. I'm out of ideas. Torqued down to 35lbs on both bolts (drain and fill). Thoughts before I take this in? Is there a vent maybe that is purging a possible overfill?

I changed the trans fluid too (drained and added 5qts of NS-2). Not sure if that matters.

[ImStricken06]

is there a leak, on the ground, or do you just smell it? that smell will be there for a while. mine lasted almost 500miles, before it went away. that doesnt mean you have leak. also there is oil on the threads, and it will creep out for an added few drops.

spray down the bolt holes with brake fluid cleaner. wipe, and spray again. let it dry. come back in a few miles and see if its actually leaking. i doubt it.

my differential case did the same thing. it was simply a few droplets that seeped out through the threads.

[unistang]

At this point, I just smell it really. Before I got the gaskets from Nissan there was a visible leak. I probably used half a can of brake cleaner to clean the case an exhaust which is why I was confused. If I let the car idle for an extended period of time it seems to clear up until I drive again. Is there anywhere else it could be leaking from? I don't see how this could happen unless the old gasket scored the mating surface or something. Is 35lbs the correct torque?

[ImStricken06]

dude its impossible to NOT get the fluid onto the exhaust pipe. its apart of the design. it super thick oil, 70+weight and its not going anywhere anytime soon. its designed ti withstand high temps. i go through this everytime i do that darn drain.

[unistang]

OK. I'll take your word. Appreciate the reply.

[ImStricken06]

anytime. keep me updated

[phmichel]

Anyone ever replaced the transfer case main seal? Mine's leaking and out of warranty. Dealer wants $650. Removing the TC is easy enough. Looks like the cover just pops off to expose seal an o-ring. Anyone done it?