rXter

04 with 35K miles. Got the 35K dealer service, which included changing the trans fluid (manual). Whole car smelled like sulpher on teh drive home. Got progressively worse. I was driving to work with the windows open. Called dealer - hum, huh, never heard of that. Typical idiot nice guy answering the phones.

Anyway, turns out that this dealer had seen 3 of these complaints in the past week. My guess is that they are overfilling the trans as it fills from the bottom. Upon use (especially if you are working it hard)the fluid leaks out and cooks off.

The fix was to replace the plastic trim piece that holds the leather boot. Mech told me that Mzda put out a service bulletin. Anyone see that? It's not in the forum link.

Well guess what. After another 50 miles its back. Not as bad as before but back.

I'll let you know how this one goes.

Nubo

It doesn't take much gear oil to reek. Unless you spot a leak, it's probably just residual oil from the change. Mechanic getting a little on their hands and touching the exhaust, for example, will leave a noticeable odor for a couple of weeks. I'd double check to make sure there was no leaking going on. If not, then the smell should resolve on its own.

rXter

Thanks Nubo. I'm taking it in next week - He said that this time around they are going to replace the rubber boot - duh. I asked why he didn't do that the first time - 'the service bulletin didn't say to'. I guess its against company policy to actually think.


Having them do the seat backs (service bulletin from 2004) while I'm at it - the warrenty will expire soon and I was just too lazy before. I sure hope they still honor that old bulletin.

rXter

They replaced the rubber boot this time. It is actually a piece of metal encased in runner that acts as a seal.

The smell is better this time around, but still comes on strong when the revs break 400.

Anyone suffering through this? I saw some other posts but nothing recently. Would love to know what others may have done to address this. My dealer is about out of ideas...

Thanks

Joe

LionZoo

I made a big thread about it. I solved it by changing the rubber boot as well as the leather boot. In my opinion, with how the tranny is designed, this issue is unavoidable. What happens is the fluid works itself up to the shifter turret and the heat from the transmission evaporates the fluid and contaminates the boots. After that, your only real solution is to change the boots.

dillsrotary

I agree with it being unavoidable, i had the same and had it disappear after about 5000 miles

rXter

Thanks Zoo - I reread your post and replied with a question. I agree with your assessment that there is some contamination through the boot that is tough to fix. Design flaw. Unfortunately the dealer will likely give up on it before they ever fix it. I am going to give them the summary of your thread and tell them to clean, clean, clean everything inside and out (I don't see why I should have to detail the car to purge it of something the dealer created), especially the underside of the leather boot tray, and to replace the leather boot, again. Maybe that will keep the stink down long enough for me to sell the car. I love the way the 8 drives, but I am not going to deal with this for the life of the car.

Icemark

Are you sure it is a sulfur smell, and not a gear oil smell?

If the wrong gear oil was used and the gear oil overheated, you would get the oil breaking down and a increase in the sulfur oxide and sulfuric acid. This wears syncros fast (this used to be a big issue on the 2nd gen RX-7 which used brass syncros- wrong gear oil and if the gear oil temp exceeds 250F and the 2nd gen syncros were toast after as little as 10,000 miles).

rXter

Took it in for 4th time. They "found" some seepage along the seals. No, really? Anyway, they replaced the seal, the shift post, and the rubber and leather boots, again. 200 miles and so far so good. The car smells a little funky, but I think that's just me Seriously I need to detail it as I have not done that since it went sulpher on me. Fingers crossed.

rXter

Its baaaack $%^&*

The stink stayed away for a couple hundred miles. It had been a bit cooler here in SoCal so that may have contributed. Anyway, the stink is back. Not as bad as before, but definately there.

I have the car into the dealer for the 4th time now for this problem - they don't have a clue. They have 3 or 4 8's coming in for the same problem and don't know what to do.

Seems to me that the answer is

1) new rubber everywhere - done
2) use non-sulpher based lube - pending
3) clean it up
4) new leather boot
5) clean it again
6) beers and prayer

Anyone found a non-sulpher lube that might not stink when it heats? I can live with an oily smell, but not the rotten eggs stuff.

Nubo

This only started after the service? I'm not sure how that would cause such issues with seals and boots. The oil drains out the bottom and is put in a hole near the top of the case; I don't see how it would run up the case into the shifter area or why "seepage" would occur after the service, unless they overfilled the fluids? Or maybe they take a shortcut and try to fill through the shifter? I'd really be curious if their procedure calls for more than just removal of the drain and filler plugs.

Of all these RX-8 that are coming in with the same problem, did they all have previous service on the transmission? The point in common would then be the dealership.

There should be no need for a "non-smelly" gear lube. If there's a persistent leak they need to fix it. If it's a matter of overfill then that's just sloppiness on their part. If they don't know what to do they should go back to mechanics' school.

rXter

The latest in the saga.

To be clear my dealership has 2 or 3 of these situations. However, according to dealer "Mazda" is seeing "a lot" of this. So they have a new procedure.

They checked the entire trans housing for leaks - nothing. They did find some residual towards the rear end of the housing and cleaned it up. They placed a piece of foam between the housing and the interior shift boot assembly - that is the new Mazda procedure.

My test is simple - remove the shift **** and sniff. After the service it smelled clean. 2 days later (about 60 miles) and it stinks again. Jeez. Its not as bad, but the story here is that it becomes progressively worse as the leather boot becomes saturated. I think I'm on boot #5 at this point.

And under brisk acceleration with high RPM the stink is noticable while driving. Nothing crazy, just dshifting to 5 and punching it to pass on the freeway - there it is again.

My other solution was to get it clean, drive it home, wash it, detail it, and sell it. Problem is that the market has dropped out on this car. The typical ask prices on autotrader went from about 17-18K in Oct 08 to 13K in Jan 09. So that option is gone. So I paid some more cash to extend the warrenty. I figure that this is going to be part of the regular maintenance - change the oil and filter and shift boot, every 3K miles.

Any additional ideas are welcome. At this point I am starting to run out of energy on the whole thing. Maybe cut the top, reinforce the box, and run it as an open top coupe. Anyone done anything crazy like that?

Thanks Joe

Razz1

Jack up the car. Get brake cleaner. spray and wash with hose.

Only way to solve the problem is to clean it your self.

I believe if the boot is getting wet it is over filled.

I use Mobile One.

Maybe you need to use that type of oil.

Nubo

Raise a stink (sorry) with the dealer. No way you should have to live with this if the car is under warranty.

rXter

Agree Nubo. When I take it in I unscrew the shift **** and make the service guy take a wiff. That seems to get his attention. I worry that eventually they'll tell me to buzz off - can't fix it and Mazda won't pay for it - smell is very subjective you know... blah blah. So far they have been good about this but at some point it becomes pointless.

Razz1

At that time when it is pointless.

Clean the tranny yourself.

climacus

This is sadly quite normal on this car. Just give it a couple of months and it will go away on it's own.

laythor

or read 16 posts and see he's been going on with this issue for 4 months

dmc27

Same problem for me when I changed @ 30k. But it was minimal and a went away. I still notice again any time it is warm enough to open the windows but it is very slight and gone quickly (or maybe I get used to it again quickly?)

However, mine is just a slightly sweet-ish gear oil smell with no heavy sulfur smell. Is there any chance the dealership is using garbage gear oil? (if you answered "no" you need serious help ) I use Redline fluid, and I have a mechanic that rocks, so I know he's not giving me "dealership quality" work. Maybe the solution is to not rely on the dealership.

Razz1

Sulfur acts as a lubricant. It quickly penetrates metals.

They over filled it plain and simple.

Just like changing oil, they remove the drain plug and put it back in.

They never clean the residue oil.

In-experienced mechanics.

You can not spill or overfill the gear fluid period.

Impossible not to spill as per re-fill instructions. You need to clean 100% of it.

When I do it by hand pump, you just barley fill it so it comes out the over fill hole.

They probably use some big *** pump and overfill way too much. Wipe clean and they are done.

Here is the problem:

Look at a glass of water. See how it sits? Notice the curve> Problem is when they overfill the fluid is just below the over fill hole.

When you drive... the fluid expands... moves and comes out the over flow.

You bring it in, they clean and same thing happens agin.

Its overfilled plain and simple.

Try using baking soda to get rid of the smell. Use brake cleaner or penetrating solvent to clean. You must get the oil out of the metal pours.


Eventually the smell will go away once the fluid has receeded to a point that it will not come out the over flow hole.

This thing about seals is all bull ****.

It worked before you brought it in. You fill from the bottom. It was sealed all along. Seal doesn't change by adding and removing oil.

Of course as mentioned.. If they filled from the top then thats a problem. because they did it incorrectly.

rXter

Agree. Its gets a little better every time they clean it, and of course I've burned a bit more off as well. Seemed to be the worst (after they had tried to fix it a couple of times) when I was really, really on the engine (say, 5500 - 6000 uphill at 85 in 5th hunting for breaks in traffic for 30 seconds or so - anyway). That will definately heat the tranny up, and another drop comes out.

I agree with your diagnosis Razz. Problem is a tiny amount of this stuff stinks like all day. It is getting better, but must be costing Mazda a fortune in warranty work - oh well too bad huh? Gives me a change to beat the s#$% out of thier rentals when its in the shop....

I've got about 200 miles on since the last 'fix'. I detailed her thoroughly over the weekend and so far the smell is better. I'll let you all know how she progresses. Thanks for the interest and ideas.

living the dream

i am glad to hear that i am not the only one with this problem!

changed my tranny and rear diff fluid the other day (royal purple 75-90 gear oil (in the tanns and the diff) i called mazda and they said that its fine to use the same weight in both!

just want to see what everyone else says about that

but drove my car 400 miles today and that was all i smelt

stoped several times to make sure i wasnt leaking any fluids

but it was fine

anyone have an exact solution to this problem?

because iam stuck on what to do...try a thinner weight in the tranny but thats what it recommends?

just very confused

thanks for any help i may get!!!

dmc27

MM powerwashes his. If you can do that it will solve your problem.


The rest of us make sure everything is clean and free of excess and then suck it up for a week or three until it dissipates.


And yes, same fluid for trans & diff is fine.

2tone

iTrader: (3)

i noticed this smell for the 1st time when i swapped out the oem for the afe short shifter. didn't change any fluids, but i'm sure i wasn't careful enough to prevent what was on the oem shifter from touching everything else.

like others say, it's harsh at first, and under hard driving, but either it goes away w/ the drive or you get used to it. it's only been a week or two for me, so i'll just keep an eye on it for now...

rXter

60-day Update: 800 miles or so. No really wicked nasty stench from hell anymore under heavy acceleration or high RPMs (and I have been driving it like I stole it recently for some reason). There is a bit of a 'soaked in' smell that I can't seem to get rid of no matter what. I open the window every 5 to 10 minutes and it is manageable.

I unscrewed the shift **** today and there is the faintest hint of funk. I think if I can convince the dealer to clean it and replace the materials 1 more time I'll be good. If I every get that stuff changed again I'll be watching and screaming all the time.

I am convinced that Razz is correct - seals were fine and they overfilled. Reminds me to always check the simple stuff first.

Thanks for the help. Looks like we are on the mend, finally.