[threeputte]

1999 FXDX-15000 miles. Transmission leak, two attempts at local H-D to fix (no success). At bike speed shop undergoing fourth tear-down currently. All seals, gaskets, and bearings replaced. Appears to leak at or near 'Quad-seal' area, but very difficult to pin-point. Oil appears on drive belt and guard, and all over wheel and fender. It's a mess. Over $1,000 invested....(sick).
Assuming the work is being done correctly, is there any information of 'unusual' conditions that may cause this leak problem. Rumors of porosity problems with the trans case itself are out there, but, unsubstantiated. Shaft run-out's, and diameter tolerances will be checked prior to re-assembly. Any suggestions, greatly appreciated!

 

[HIPPO]

Casting porosity is not a rumor, but it is more unusual with gearbox cases then with engine cases. It also tends to show when the bike is new as opposed to several years later.

 

[HIPPO]

Shafts can be bent by hammering the bike. It doesn't sound like it but it wouldn't be the first time a gearbox is disassembled because it puked oil intermittently due to a partially blocked breather. Check the seals in the inner primary.

 

[threeputte]

Thanks for your input, Hippo. A new development is a hair-line crack in the main gear. The crack is directly in the 'root' of the spline where the drive sprocket attached. It was discovered during disassembly mainly because the threaded portion of the main gear shaft broke when loosening the nut. It appears the crack may have been an inclusion or weakness in the casting from the beginning, but took this long to manifest itself. Bike going back together, will know conclusively soon.