96 960 Oil leaks everywhere!

[ctlytle]

I've been everywhere on the web, and to three mechanics. All say the same thing...but need to confirm ... losing lots of oil from leaks. Common wisdom is that a) its' tie flame trap, b) it's the oil box, c) it's a leaking oil cap seal. Two mechanics said the oil box/flame trap need to be replaced at some 4 hrs / $500. I did replace the oil cap gasket (there was oil pooling up under the plug cover. BUT THE THING IS.... I"ve checked the Flame trap and it's clear, and the hose running to it from the oil box is not blocked either....I blow thru it and hear the air going into the engine (use an air hose & tool). QUESTION: Can the oil box still be leaking even if the air is flowing properly...not building up pressure. Don't want to fix what's not broken.

the other theory is that the oil is coming from the Head, such as it is. Seem like there are two layers of head, and it can be leaking out of the bolts holding the two halves together, or coming up thru the head in some manner. Any counsel most welcome and many thanks in advance!

[sanfelice]

more than likely, it is the rear main seal. I have owned 3 960s and they all leaked from the rear main seal. in fact, the two that I currently own are leaking, but only one is on the road at the moment. the other I changed to a high mileage oil and that seems to help. but, if the leak is quite bad, nothing but a new seal will help. if it is any consolation, they will all leak at some point...

[ctlytle]

A possibility, but I assume the real main seal leak would show up near the rear of the engine...it's currently showing up on the oil box and in various locations... but mainly under the drivers side mid engine...like, under the oil box/flame trap. And, two mechanics (one Volvo dealer) said it was the oil box. So Im wondering if it's possible for the oil box to leak even though air flows freely through the PCV system..the Oil Box and the Flame Trap are clear for fumes/air to pass so it's not building up any pressure to force oil out elsewhere? Thanks much

[JDS60R]

Place a rubber glove over the hole where you just removed the oil filler cap from and run the engine. See if it pulls the glove in or fills it up.

If it fills (car warmed up) then you have too much pressure from oil trap/blowby etc). If it sucks in then your oil trap and blowby are fine. Then look at replacing the leaking seals or using a can of AT-205 until you can get to replacing the seals.

[ctlytle]

Great suggestion. Tried it. No push or sucking to note seems fairly neutral...but definitely no filling or blow out. I would then assume that its probably not the oil breather box or flame trap...although perhaps it should be sucking the glove in more?? I'll get the AT205....whatever that is, and see what happens. How big a deal is replacing the seals....sounds like a job for a pro, not my backyard skills....Thanks

[donis222]

Mine was leaking at the lower (drain or return) hose from the oil trap. There is a hose that runs back to near the dip stick tube. It takes me 2 hours to R & R the manifold. They all get hard as PVC.