Ron,
After looking at your picture I can tell you one problem you have right now. The gear housing is not correctly mated to the fan housing. The input shaft should not be at the bottom of the oil sump. It needs to be rotated 1/3 turn clockwise. That gets the input shaft above the oil level. The gears get lubricated by splash action. When I re-did mine, I was having issues with the oil coming out of all the shafts. I, like whoever last reassembled yours tried to align it so the lettering was upright. Mike-hr told me he didn't think it was right, then on further inspection we found a small lubrication port where the input shaft goes into the housing and it was pointed at about 7 o-clock (which I'm guessing yours is to?). Anyway, once I turned it 1/3 clockwise the leakiness went way down. It's still leaking a very small amount at the lowest bolt hole that joins the two half's, but it's minimal. Is there also a plug at 6 o-clock in addition to the one we see in the pic? Mine had two, so there's now one at the top, and one at about 7 or 8 o-clock that has a little petcock still in it. I open the petcock and dump non-detergent 30w in the top until it starts to come out of the petcock and that's where I leave it. I must say I'm still pretty much in love with my blower. It's a good one, and I think the Royal Cheif is pretty much the cadillac of the bunch.
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