Gearbox leak

Post by **airhead** » 17 Feb 2008, 23:08

Hi folks. Ive a 1.6TD Syncro with 104,000km's on the clock. Couple of problems. I was under my van today (I got the chance to put it over a pit so I did) and I saw that the bottom of my gearbox was covered in fresh oil. Following the source of the leak led me to the left CV joint, or rather the plate on the side of the gearbox from which the output comes. There's a gap between it and the face its mounted on. The other side does not have this gap. Now aside from that the gear shifting becomes stiff and nasty after a long fast drive and it becomes difficult to get it out of gear, but it will go into gear no problem. I replaced the gearbox oil recently because this stiff shifting has been going on quite a while. Around as long as the grating noise that also shows its ugly head after a long fast drive, but its only noticable when Im doing a bit of speed (maybe 40mph+). Its a sort of rattly gratey sound and only happens when I have the power on. So I let go of the accelerator and it stops. Now, the leak only happens as well when Im driving. I know this because Ive never had a pool of oil under the van in the morning or even after its been sitting for a while. If I did I would have raised this issue a while ago. Now, the gearbox oil I used when I replaced it was Carlube 75w90 oil. The noise and stiff shifting as I said have been going on long before I replaced the oil. I dont know about the leak though. I never noticed it before. Even when I changed the oil. What should I do? Tighten the plate, top up the oil and hope for the best or borrow a car from work, take the van off the road and remove the gearbox for further inspection? I really dont want to have to do this. Its a very big and difficult job for me. I could do with some advice here. I think this happened cause I put my new captains chairs in and every time I do something nice on the van it bites me in the ass. Cheers.

PS: I took pics of the location of the leak and will upload them tomorrow.

Post by **airhead** » 18 Feb 2008, 15:27

[img:500:375]http://photos4.pix.ie/51/4E/514EB139ECD ... 9C-500.jpg[/img]

In this one you can see the gap between the plate behind the CV joint and the gearbox casing.
[img:500:375]http://photos4.pix.ie/08/D8/08D893C36E3 ... 43-500.jpg[/img]

And here's how the whole thing should look...
[img:500:375]http://photos3.pix.ie/2C/95/2C950334AE7 ... 4A-500.jpg[/img]

Im fairly eager to sort this out before it comes to a head, so any help at all would be greatly appreciated. Thanks.

Post by **toomanytoys** » 18 Feb 2008, 16:18

You better speak with Aidan ASAP... or it will turn very expensive...
that "dry" flange seems awfullt close to the retainer... and shifting problems means something is quite worn..
Grating

isnt normal or good..

whst was the sump plug like when you took it out? oil condition and colour?

Post by **airhead** » 18 Feb 2008, 16:43

The sump plug didn't have much metal on it. I suppose equivalent to a level teaspoon full! The oil was murky and grey. I take it the plate that I referred to is the retainer and the flange is what the CV joint attaches to? If so, it didnt seem alarmingly close when I was under there. Maybe the grating noise is the flange rubbing against the retainer on the side where the leak is because they were quite close, and possibly under power they might end up touching.

Post by **camper** » 18 Feb 2008, 17:47

What you have missing is a plastic or metal flange plate.This is screwed on to the gearbox by two phillips screws.Its purpose is to act as a dust cover and locking for a fine screwed metal part to adjust the diffrential setting.There is a oil flange seal that seats behind the constant velocity input shaft which is very likely the cause of your oil leak.To replace the gearbox flange oil seals look on the wiki .

Post by **airhead** » 18 Feb 2008, 18:04

Thanks, Camper. That was the reply I was after. The flange plate is there but just not tight. I just wanted to know if it was indicitave of further problems. The irritating thing about all this is it now means Ive to put more bloody gearbox oil in the thing and we all know what a pig of a job that is!

Post by **camper** » 18 Feb 2008, 18:21

If you look on the wiki it will discribe the procedure to replace the gearbox flange seals.It will discribe how to remove the oil seal.But when i replaced a flange gearbox input seal for skins a 80 90 user name. The fine screwed aluminium metal part that adjust the diffrential moved out of position on attempting to extract the worn oil seal in fact it turned on its thread.If you read a haynes manual it says put a mark on it and the box caseing i would suggest you do this then you can get it back to the right adjustment if it turns.If you are carefull even when the gearbox is topped with oil on removing the worn seal it should not leak out to much .That is what happened with skins.A new gearbox flange seal is aprox £14.00 from a main dealer.Its not such a bad job to top it up with oil just get the right tool spay some penetrating oil around the filler plug.When you manage to loosen it use a length of hose pushed inside to top it up.

Post by **toomanytoys** » 19 Feb 2008, 08:29

If that plastic retainer has been ripped out by the cv flange etc, then its entirely possible that the adjusting ring its supposed to hold has moved..
this is quite critical for the diff preload and alignment.. to tight and the bearings will heat up, scortch the oil and wear out.. Too loose, diff flops about and the ring gear and pinion eat themselves...

Like I said, have a word with Aidan.. he can supply the bits you need and talk you though what and how to check..

Post by **airhead** » 19 Feb 2008, 22:54

You're breaking my balls here man! Breaking my balls! I need some good news! I'll give Aidan a shout tomorrow from Skype and see what he can advise. Maybe the grating noise and stiff shifting are all to do with the diff being wound up.

Post by **lloyd** » 20 Feb 2008, 07:51

Breaking balls?
Need good news?

Good news: if you fix it before it crashes you may not need a new gearbox.

Post by **camper** » 20 Feb 2008, 07:57

Aidan gearbox rebuilds looks a very good service.

Post by **toomanytoys** » 20 Feb 2008, 08:46

Not breaking your balls.. but if you do insist on driving it... something WILL break.. Aidan has seen far too many mashed gearboxes now.. just through people not stopping when there is an issue...

The clearances are VERY tight in these boxes, once something starts to move, it touches other parts, which grind on more and in a very short time you have a total scrap box...

I wouldnt trust anyone else with my box.. he's done my syncro box and will be doing my 2wd box soon as well as the "spare" syncro box...

He is also doing a front diff for me too..

Post by **airhead** » 20 Feb 2008, 14:15

OK Ill give him a bell. Thanks for the advice. Tongue was firmly in cheek with the "breaking my balls" comment by the way.

Post by **airhead** » 22 Feb 2008, 10:33

Just for reference sake, the part number on the wiki is wrong. Its actually V091 301 189. Its the same for all gearboxes.