in polishing stage
Join Date: Aug 2005
Location: United Kingdom
Re: Sud Gearbox Leak - Help
This is definately not the best solution to this job - it's just the best way i could see of doing it on my car in the position it was in, and without having to remove the exhaust system and drop the back end of the engine/gearbox.
Anyway - when i took a good look at the setup under the car i thought it would be a pain to drop everything down so i did the following.
Please note : My car has a steel plate 'gearbox tailshaft' (haynes manual description - some cars must have 'cast' ones by the look of it!) this enabled me to do it this way.
Drain the gearbox oil.
With the gearbox in 2nd or 4th gear (I think - anyway make sure the gearbox shaft is 'out' as far as it will go!), i drilled a hole through the side of the tail shaft, with the hole drilled i was able to get access to the roll pin using a thin (4mm) rod from the other side of the gearbox and over the top of the exhaust.(see pics)
Its quite fiddly but you can tap the roll pin up and it just comes out of the top without fouling the 'tunnel' of the car.
From inside the car you must undo the nut and bolt and release the link rod, again its quite fiddly to get the link arm off the gearbox shaft as space is limited, i actually 'changed gear (1st 3rd??)' to gain extra space - but BE AWARE, it was quite difficult to get the gearbox shaft back 'out' to line back up with the hole you drilled.
Once this was all out, it's just a matter of getting the old seal out, if you can do it with a 'dental probe' great, i just found it was a little bit more difficult than that on my car and ended up 'destroying' the seal to remove it.
I didn't have any tools for fitting the new seal, i just used a few ring ended spanners of the correct size and a spark plug socket over the gearbox shaft to gently knock the new seal into place - and it worked a treat.
Now its just a matter of putting it all back together. Because i'd 'changed gear' i had to use a rod and hammer (located into the roll pin hole in the shaft) to knock the gearbox shaft back out to get it in the right place.
With this done you now need to grow a few more arms and a set of eyes on stalks (or ask a friend to help). Position the link arm back on the gearbox shaft - again it's quite fiddly - but it can be done without moving the gearbox shaft again. Then you need some one to hold the roll pin in position with some pliers whilst you use the rod and hammer to tap it back into place through the hole you drilled from the other side.
Reattach the link arm at the gear lever end - refill the gearbox with oil - and its job done!!
All this took me about an hour and a half - bearing in mind i was making things up as i went along. I certainly don't think it's the easiest way to do the job - but it worked for me.
It would always be easier with better access under the car and probably he best way would be to drop everything down - but that depends on how much space you have as you would need to drop the gear box far enough to get to the roll pin from the top.
Hope this helps you out - feel free to ask any questions.
Last edited by Matt.K; 16-06-07 at 14:01.
Reason: missed a bit