I have a 1993 Grand Caravan, 3.3 with 41TE Transmission. It was 278000 Km on
it. The tranny was rebuilt by a reputable tranny shop (not thru a Chrysler
dealer) at 195000 Km. All available upgrades at the time were incorporated.
The transmission has always, and still has all appearances of operating
perfectly. Regular routine fluid and filter changes at normal intervals have
been done.

About 2 weeks ago it developed a leak. I've been topping it up with correct
fluid (Mopar ATF3) to get to now when I had a chance to investigate.

It turns out the leak is from the differential cover. Something has pierced
the cover, which is made of a plastic material. The object is still imbedded
in the cover. It appears to be an internal piece. It is wire rod like in
appearance. There is about 1/8 inch exposed to the outer side, and it is
approximately 1/8 inch diameter. It is a polished silver colour. It has a
similar look to a wire coat hanger.

Although I am a very mechanical person, I would not desire to tackle at this
time, any job requiring removal of the transmission, myself at home. As the
transmission still seems to function properly, I am wondering if I might get
away with just removing the cover, installing a new (or used) cover, refill
the transmission, and go.

My concern is, what is the piece from, and might I just be waiting for a
catastrophic failure to occur unexpectedly? Does anyone who has worked on
these trannies have any idea what might have broken that would cause this?
What the piece might be from? And what future implications it might carry?
Has anyone seem this specific type of issue before?

I went through the pictures in my Factory Service Manual for the
transmission rebuild, and did not see anything that seemed to have this
round rod type of shape. Might something like this be able to have traveled
through the transmission fluid and ended up in the differential section?

If all appearances are that at least a partial rebuild would be the only way
to go, I don't want to get the van stuck in my driveway needing a long tow
to the transmission place, I would rather just drive it there and have them
do the whole job. If it seems just changing the cover might be sufficient, I
would do that myself.

Any ideas and thoughts appreciated.

Mike