Major Gearbox Oil Leak

[johny105_y2k 1]

Hi, first off i'll give you a brief overview of the situation.

89 1.6gti 1.9box

car has been going through a mini overhaul. i've done the engine up and had the gearbox reconned.

all in and ok but i lost interest in the summer, so the car hasn't moved. (0miles on the thing)

last week i decided to sort the rear brakes out as that was the only thing i was aware of for the mot that required work.

drove it forward and back ok. ( its in a tight spot ) no problem.

 

now today i decided to wash it so i was manouvering it to reverse up the tight drive and it wan't feeling right so i stopped and noticed their was oil going all over the place.

it wasn't engine oil. so i assume its something i've not done correctly.

both D/S are in speedo sender in all ok the oil is coming from the bell housing and its definetly gear oil

now i've started to rip it apart to get a better look but i've lost light.

output shaft seal? i was thinking but would one fail instantly? as it was ok last week .....

any input is greatly accepted as i'm baffled

 

 

thankyou .

 

johny

 

 

p.s

just had a thought allthough i doubt it but i might aswell put it out there. if i'd overfilled it with oil could that of done it?

i put just under 2 litres in which i thought was ok?

Edited October 31, 2009 by johny105_y2k

[Tom Fenton 1,542]

Bugger, it does sound like its the input shaft seal, I guess you'll have to rip it to bits and see what is what.

[bigsheep 5]

Bugger, it does sound like its the input shaft seal, I guess you'll have to rip it to bits and see what is what.

 

Were there any grinding noises? When mine did this and lost alot of oil the diff had put a hole

in the inner wall of the bellhousing.... Apparantly it is a common problem for the diff pinion to go

walkies and smash the casting open.

[johny105_y2k 1]

not that i can recall .

there was a pop then it didn't feel right so i stopped it.

i jacked it up and could spin both front wheels in every gear.?

 

i was planning on stripping today but its ralphing it down so next opertunity is next weekend

any other thoughts?

 

johny

[bigsheep 5]

If its deffinately gear oil then the input seal or the diff housing are the only options.

 

It is possible that the input seal was not seated properly and has either torn or popped out or that the input shaft bearing is not seated correctly.

 

Did you say that this is a 'reconditioned' gearbox?

 

Oli

[johny105_y2k 1]

yeah its a reconned gearbox with 0miles on it .

dont know what the diff was like but i'll assume it was checked , but i know all too well things can just 'go'

all i've done is paint it, fit it and fill it with oil.

 

i've done a bit of research and the oil level is below the input seal level so it looks like its the diff pinion thats gone walkies.

which frankly is a big kick in the teeth!

 

 

johny

[bigsheep 5]

Mine did this as the roll pin that holds the planet gear shaft in place falls out or wears through allowing the shaft to wander which

usually hits the casting ribs causing a chunk of the gearbox casting to shatter outwards usually in the direction of the bellhousing.

 

I had my internals rebuilt in a good casing by Cumbria Transmitions, there is a mod that they make to stop it happening again.

 

Oli

[johny105_y2k 1]

touch wood i should be able to get a case and a decent diff and swap it all over.

[johny105_y2k 1]

well its a hole in the inner bell housing , allthough it is small i'm going to get the welder at work to tig it up , there is minimal damage to the gears the roll pin had worked its way through to the other side so i'll see about sorting that issue also .

 

what are you opinions on tig welding the hole then?

Edited November 1, 2009 by johny105_y2k

[bigsheep 5]

Good luck with the welding, aluminium castings are very difficult to weld.

[johny105_y2k 1]

well this guy is a prof welder and is ready for retirement so if he cant do it then i'd bet no one could.

plus 95%of his work is with ally so i trust him. but i've nothing to lose either way!

Edited November 1, 2009 by johny105_y2k

[Tom Fenton 1,542]

As you say, you've nothing to lose, just get it as clean as you possibly can to give your man the best chance.

[johny105_y2k 1]

well its done he said it'd be best not to tig it and gas would be best (why i dont know?)

and it kept cracking whilst it was cooling:(

so he's had to build it up high and now the diff wheel catches slightly i've sanded it down but i think i'm going to have to get another case.

 

so if anyone has an old knacked box that i can transplant the gears out of see my wanted thread going up shortly.

 

 

also are all the cases the same i.e BE1 + 3? mine has lift up rev (BE1 corrrect me if i'm wrong)

 

 

 

 

johny