TRNW-2: VW O9G mysterious leak

[Chris and Cathy Kershaw]

Right next to that bolt maybe a torque issue? I remember cracking the side
cover on a 4t65 at the bottom by the torx bolts, proper torque and sequence
would prevent it.

On Tue, Dec 16, 2025 at 3:12 PM Steve Everett via trnw2 <trnw2 at trnw.net>
wrote:

>  We put dye in the fluid and finally verified where its leaking from, the
> crease where the arrow points,  there apparently is a crack there , can't
> see it with your naked eye, but the dye was seeping from that crack, same
> place the other bellhousing was apparently leaking from,  we're going to
> see if we can get it tig welded by a machine shop locally
>
>     there is a pressure passageway on the other side of that crease,  that
> is fed by a passageway on the pump body , I've since discovered the
> valvebody was replaced when it was originally built, there is more than one
> valvebody for these units,  I don't know if there is a difference in
> pressures or variations that might explain this ?  I know there are a
> couple of holes different between VB's relating to lube supply ?
>
>    Steve
>
> On Tue, Dec 16, 2025 at 2:48 PM Donald Day <trnsmaster at verizon.net> wrote:
>
>> If bell is porous clean good then coat with epoxy
>>
>>
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>> On Tuesday, December 16, 2025, 10:24 AM, Steve Everett via trnw2 <
>> trnw2 at trnw.net> wrote:
>>
>>   I have an 09 Jetta with a O9G , originally built at another shop, 2
>> months after being built it had a small leak from inside the bellhousing,
>> small enough that sitting running after 5 minutes there will be one drop at
>> the inspection hole at the bottom of the bellhousing,  when you look up
>> inside that hole the fluid seems to be seeping from the right side up
>> inside the bell,  we pulled the unit, and fluid appeared to be coming from
>> around the uppermost bolt on the right side,  (red dot in picture
>> attached)  I removed the bellhousing, cleaned everything, resealed the bell
>> and used silicone on all the bolts,  reinstalled unit and still had the
>> leak,  pulled again,  this time I thought maybe the case was porous in the
>> are above and to the left of the bolt, as fluid appeared to be in that
>> area,  I cleaned everything with brake clean, coated that area with JB
>> weld, resealed the same bolt again, installed a different converter,,,
>> installed unit,    same leak again,
>>        took a week or so for us to find another unit,  removed
>> bellhousing from core unit, cleaned and resealed everything related to the
>> different bellhousing,   reinstalled,   still have same leak,
>>
>>   Different bellhousing, changed attaching bolts the last time around,
>> using ultra grey silicone to seal everything,  plenty of silicone on all
>> the bolts, changed converters once, ( fluid is not all over inside of
>> bellhousing , only on right side, so I don't believe its converter related)
>>
>>   only explanation would be two different bellhousing being porous in
>> same area ?    in the picture attached the fluid originates in the area
>> where the red dot is
>>
>>  Anyone ever seen something like this ?
>>
>>    Steve
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