1989 2.4L gearcase leak!!

[19bee70]

Hi to my engine gurus! Seems I have a neverending problem with my gearcase leaking oil. Now I suspect it's gear lube and not fuel/oil residue. It is leaking from both sides of the gearcase side covers. You know...those 1' wide by about 5' long covers on the gearcase below the seam with the midsection. I can't for the life of me believe it's oil as a result of expansion, although it does sit in the sun all day. It just constantly drips. It hangs vertical and when I pulled the side covers off to reseal them I noticed elongated o-rings that are supposed to seal those covers. What actually passes behind those covers??? Is there supposed to be an oil passage there that accounts for the oil leak and I just need to reseal it?? HELP?
PS...yes, it's a 2-stroke if it has any relevence

 

[Maxz695]

Re: 1989 2.4L gearcase leak!!

It might not be much help but, when you lift the engine to tow the carbs spill out fuel due to the floats not being level. This is a common thing and cannot be avoided. The only way that I can "Guess" that it is the lower unit would be to empty the oil in the gearcase and see if theres water in it

 

[j_martin]

Re: 1989 2.4L gearcase leak!!

Gear lube and engine oily mess have distinctly different odors. Get a little on your finger and smell it. Then crack the lower (drain) screw on the gear case and get a drop out of there. Examine it for water or milkiness. It should be clear or maybe black if dirty and definitely grease, not water. Smell that. I'll bet they're entirely different.

Unburned fuel gets into the exhaust system, picks up some soot and the gasoline evaporates, leaving an oily mess that can sometimes drip from the LU.

BTW, when you fill the gearcase, you pump it in from the bottom till it just runs out the top, then leisurely remove the filling tube and put the bottom screw in. The object is to spill approximately 1 oz. of gear lube so there's head space above it. Then install the top (vent) and tighten both plugs. It's in the book.

 

[19bee70]

Re: 1989 2.4L gearcase leak!!

I'm checking the gearlube ASAP! I guess if water was getting in, the oil level could rise and thereby leak out. It's just funny that the leakage isnt evident when I pull the boat out of the lake but a day later while its sitting on the trailer. I understand the concept of filling from the bottom. No problem there. I'll be back shortly to post results of my inspection!

 

[Faztbullet]

Re: 1989 2.4L gearcase leak!!

You got the CLE unit so if you have oil from covers its a waterpump or shift shaft seal. As J stated it could be unburnt fuel from say a carb slightly fllooding when tilted and trailered, check the oil and if contaminated drop unit and inspect.

 

[19bee70]

Re: 1989 2.4L gearcase leak!!

OK Faztbullet, the summary is: I drained the gear oil and yes it was a bit cloudy but only a couple of oz. came out, not the 21oz my book calls for. I filled it back up. I ran all the fuel out of the carbs until the engine stalled. I've tilted it and down a few times and no oil leak. I'm thinkin it's probably more likely the fuel drainage more than anything else. Yeh, the gearcase seems to be sealed since there is no oil coming out. It leaked around those side covers and if those covers cover the exhaust system then I could see the fuel/oil drainage theory. I was baffled on the low oil and NO excess water coming out with the oil. Is it true that the gearcase build pressure while in use and that maybe the oil could get forced out around a seal and yet no water could seep in while not running? Anyone with thoughts or experiences want to chime in?

 

[Faztbullet]

Re: 1989 2.4L gearcase leak!!

Its true the heat/oil expansion will pressurize the gearcase and oil can leak out, but when it cools it forms a vacuum which will draw in water around the defective seal/s. Did you put 21 oz back in it or just a few oz's? You did put the Hi performance lube?

 

[19bee70]

Re: 1989 2.4L gearcase leak!!

YEP...2 tubes but I'm afraid I don't know if it was hi-po or not. I didn't pay attention to that part
What would I be jeopardizing by running this "unknown", really? I will say that having tilted a few times and let it sit in the sun (the normal setup) , there hasn't been any oil leaking out the gearcase by the inspection plates or the seam. Since I have NOT filled the carbs since running it dry, I would have to think maybe the leak I have is nothing more than the residual oil/fuel leaking down the exhaust passage in the midsection and maybe out the side seam. I do have to tilt to trailer it home and the carbs are still full then. Next time out at the lake, I'll run the carbs dry, tilt, and bring it home to see if I get any leakage. I have a feeling I'm getting close to the answer!