AAZ conversion with leaky sump

[H.Mc]

Hi All, after a good few months we finally finsihed my AAZ conversion on my van... it runs beautifully and can now travel up hills on the motorway with out it turning in to a white knuckle ride!!!!
But we have an oil leak from around the sump. We tried to re fit a new sump gasket but found that we could no longer get to two of the sump bolts right at the back by the bell housing. As the flywheel covers up the bolts. Do we drop the gearbox or is it an engine out job. Help what is the easiest way to stop the leak Advise needed CHEERS

[Oldiebut goodie]

It isn't easy to get to those two - with a lot of perseverance they will come out and go back. I think I made a square on a piece of steel bar to take a 1/4" drive socket to do it. A right pig of a job though. Some people have said that they didn't refit them and had no leaks though. Are you using the rubber gasket with the windage tray or the standard JX style gasket? If you are using the rubber one be aware that the bolts are slightly longer to compensate for the thicker gasket.

[Trunkster]

AZZ is a good choice but get an oil cooler if you having got one! BW expensive £400 but well worth it. It could save you a fortune. Experience

[H.Mc]

Thanks.... have new paper gasket so will give it another go... just rather exssesive to take engine out to get to two bolts!!!

[ELVIS]

Make sure you do up the two bellhousing to sump bolts before you fully tighten the smaller sump bolts.

I've always managed the two awkward bolts using a 1/4" drive with a 12" wobble bar extension

[dekhelia]

Thanks.... have new paper gasket so will give it another go... just rather exssesive to take engine out to get to two bolts!!!

You don't need to take either engine or gearbox out to get to these bolts.

Just a bit of patience, the right tools (1/4" drive socket set with an extension), and a good light source.

Don't tighten anything fully until you've got all the bolts to bite.

What's this about a paper gasket? Isn't it supposed to be rubber, with the special VAG sealant stuff???

[Oldiebut goodie]

Rubber if you have the windage tray (integral with the tray) if not - the paper one using the bare JX sump.

[dekhelia]

News to me. I have a rubber gasket (without windage tray), and bolster the seal with the VAG-prescribed gunk.

On an engine as rattly as these, I'd give a paper gasket 5 minutes before it springs a leak.

Ok - 6, then.

[HarryMann]

Yes those set screws come out with correct 1/4" tools.
I use rubber gasket and longer screws.