GTI BOX- AAARRRRRHHHH!!!!-NOW WITH PICS!!

dubbprince · Post by **dubbprince** » Sat Nov 17, 2007 4:58 pm

Drove the car last night to go pick up some number plates and it was fine!
goes into gear perfect and makes no whining noises at all.

Picked up the plates and hopped back in the car only to find 2mins later it sounds like my front pipe was rattling on my subframe- was not the case!

Took the box off today because the clutch was slipping badly on my way home, i couldn't pick up any speed!! just kept revving its ass off...

figured it must be the friction plate or the release bearing...so took the box off.

OIL JUST POURED OUT OF THE INSIDE OF THE BELL HOUSING! where the clutch components/release bearing all are...this explains the clutch slipping! the noises...

BUT...how the hell did the oil get inside there??

I have the car is in pieces- need to re-fit it all...but don't want to do it knowing my box might have gone

GTI V · Post by **GTI V** » Sat Nov 17, 2007 6:26 pm

Check the oil seal for tha mainfshaft of the gearbox. Should be 2, one larger one, and another penny sized one. The largerone would be the more likelyhood of failing.

Also maybe, but very unlikely, the rear crank seal.

mk5coz · Post by **mk5coz** » Sat Nov 17, 2007 7:04 pm

check for damage to bell housing i once took a car apart at work and the springs on the clutch had snapped and actually sliced through the gearbox letting all the oil into the bell housing to which it trashed the whole box and clutch.

dubbprince · Post by **dubbprince** » Sat Nov 17, 2007 7:14 pm

there is no damage to the bell housing...the main shaft- are the seals hidden inside the gearbox for this? or apparent when you look at the shaft inside the box...couldn't see any breakdown on the area round it.

I'll get a a pics up...

GTI V · Post by **GTI V** » Sat Nov 17, 2007 9:36 pm

The seals on the gearbox side should be visible as you look at the shaft where the clutch will slide on to (splines)

And the crank seal should be visible looking at the engine

dubbprince · Post by **dubbprince** » Sun Nov 18, 2007 1:24 pm

its definately gearbox oil that came out...it was very thin in viscosity, almost like brake fluid and had clutch friction plate metal particles inside it, so came out like liquid metal lol.

I've now got photos...so if you can, let me know exactly what the shaft seal looks like...

My guess is! its sat behind the centre part held with 3 torx style bolts! (see photo)...

The crank seal- is that in the middle of the flywheel? so as if your looking through the middle of the clutch plate?

1 GTI · Post by **1 GTI** » Sun Nov 18, 2007 4:47 pm

Well done for getting your box out mate. Why have you taken your bumper, radiatar and lights off to do it though? I appreciate it's very awkward to do.

dubbprince · Post by **dubbprince** » Sun Nov 18, 2007 5:02 pm

awkward isn't the word...i hate being frustrated doing things like this...and i know how difficult it was when i took the box out of my mk3 polo where the front slam panel doesn't come off!

It'll be easier when i put the box back in!

So...can anyone shed any more light?

dubbprince · Post by **dubbprince** » Sun Nov 18, 2007 7:50 pm

GTI-V- do you know what the part number is for the input shaft seal?

vdubit · Post by **vdubit** » Mon Nov 19, 2007 7:33 pm

Part number required 085 141 733 B

Common as muck and p*** easy to fit.

dubbprince · Post by **dubbprince** » Mon Nov 19, 2007 9:19 pm

hmm the seal part number i have is:

085 311 113...have i been given the wrong one??

dubbprince · Post by **dubbprince** » Tue Nov 20, 2007 8:40 pm

Bump...

dubbprince · Post by **dubbprince** » Wed Nov 21, 2007 6:46 pm

narp! cheers for the responses though lads. lol...

The box had exactly 2-2.5ltrs in it...the breather is dry, but the area right near the release bearing isn't. I've just had an expert opinion and it seems either the main shaft bearings have gone and the shaft isn't turning straight! OR the seal just needs replacing, so gonna check for play in the input shaft first...

Good thing is! i know a guy who can rebuild it for Â£60..GET IN!!

dubbprince · Post by **dubbprince** » Thu Nov 22, 2007 10:07 pm

REALLY wasn't expecting this...but replaced the seal only to find a small 5mm hole inside the gearbox casing and a hairline crack!!

Looks like one of the gears inside has hit the inside of the casing and creating a fracture.

Gonna definately need a rebuild AND a new casing...BUT...

can anyone tell me if all mk5 and mk4 cases are the same?? so i can change over the gears inside my GTI box into another case?!

Post by **alexperkins** » Thu Nov 22, 2007 10:57 pm

thats nasty dude. Id stay on the lookout for a scrapped polo!