Worn gearbox flange cap

[T25Colin]

Hi everyone,

Thanks to everyone that helped me get in touch with my gearbox guy. I have been to see him today and we are working on sorting the leak from the near side of the box, the cup looks good and a new seal fitted but still leaking... When the drive shaft was taken off we saw that the seal cap behind had been worn through by the shaft pushing in to to it. It’s only done a 1000 miles on the recon box and the shaft is about 18 months old. Can I ask if anyone has experienced this before? It’s the plastic centre that sits in the flange in the side of the gearbox. I will post a picture if I can figure out how to do it.

It’s a four speed recon box on a 1.9 dg with new jk shafts. The trailing arm that side is new too so can’t see any play there.

Really welcome any ideas

Also the Vw engine Co recon water pump is leaking from the weap hole. It’s the second pump in 1500 miles. Any ideas on what to check before getting back in touch with them? The belt doesn’t seem to be too tight, I’ve had a guess and ordered an expansion cap in case it’s stuck closed and pressuring too much but pretty much stuck on what else to check.

Two questions in one thread which I hope isn’t bad etiquette!

This van really is fighting me!

[T25Colin]

The engine is recon not the pump! The pump is new!

[SurfT25]

[Aidan]

measure the driveshaft, it should be 541mm over the shaft, if it is 548mm then it is an air-cooled T25 one
is the van lowered ?
are the splines on the differential output shaft or flange excessively worn ?

[T25Colin]

Hi Aidan, no not lowered, I’ll get the tape measure out and check the length. Spline wise it’s been reconditioned and they appear ok.

[T25Colin]