Gearbox oil leak

[jumbojim]

Hi all, my first post here...

I've recently bought a '03 Polo 9n with 200k miles, and let's say it has a few "issues" that need sorting.

Top of the list is a low-level whining noise when under load in 5th gear. The gearbox is supposedly a recon fitted at 150k miles, i.e. it's done 50k miles since. I've had a look underneath and there's oil all around near the drive shaft near the gearbox. It's not dripping any noticeable oil on the ground after parking (not sure if that's a good or bad sign!). I'm no expert but at a guess it looks like the gearbox drive shaft seal is (or was!) leaking. Looking at the pics below would that be a fair assessment, or what else could it be?

I asked a local garage and without seeing the car the mechanic reckoned 2hrs to change the seal. Would that be about right?

On a separate note, the IAT sensor was o/c, which I've bodged with a fixed resistor (for now) and cleared the DTC. The MIL still comes on at key-on but goes off again after engine start. Is it waiting for a drive cycle and if so what does the ECU want to see before it will turn off the MIL?

Car details: Polo 9n 1.9D SDI, engine code: ASY.





Full size linkies here:
http://oi43.tinypic.com/2ito5z6.jpg
http://oi41.tinypic.com/9jkio6.jpg
http://oi42.tinypic.com/2mxjza8.jpg

-jumbojim

[alexperkins]

Looks like the driveshaft oil seal has gone.

I would recommend getting both sides changed (considering the cost would be little more) and a gearbox oil change. It can be done in situ, albeit its messy without removing the gearbox first.

[jumbojim]

Thanks.

The garage confirmed it was the driveshaft seal. I had them replace the seal (only that side) and drain/refill the oil.

But the thing is that the whine in 5th gear is still there. It only happens under load, even just holding the speed with light accelerator pedal is enough. As soon as I come off the gas the whine stops. It's not loud but enough to be noticeable with the radio off.

It's the first time I've used that garage too - not the friendliest experience. Kicking myself now because it's cost me money and hasn't fixed the problem I was worried about. Should I have a go myself and try overfilling it slightly? Not sure exactly what they put in except it was "EP90".

The car has a list of other (relatively minor) problems which I hope to sort out myself but if the gearbox is on the way out then I am not inclined to waste much time on anything else.

Cheers.

[alexperkins]

Overfilling the gearbox is a foolish idea as it will cause high oil pressure, and itll find its way past the seals

Its quite possible the gearbox has a dodgy 5th gear bearing, so either the box needs to be looked at by a specialist, or you learn to live with the whine lol

[Alexc]

Hi all, I have just discovered the same issue, drivers side leak from the shaft seal.

I’m happy with a spanner so will do the repair myself but have looked at a few YouTube videos and am a little uncertain on getting the shaft spline out of the gearbox.

In some it seems that I don’t need to undo any of the splined bolts, just remove the whel hub from swing arm and pull the driveshaft out from gear box and accesss the seal that way?

Can someone confirm the correct way?

[alexperkins]

You need to remove the Center bolt inside the driveshaft cup. It cannot be done without removing the driveshaft first.

[Alexc]

Thanks so that’s why I need to take the splined bolts out then, to get to the centre bolt?

Does the hub need undoing in this case then or can I leave that alone and just get it apart by undoing the splined bolts?

Novice questions I know

[alexperkins]

For sufficient access you’ll need to undo the driveshaft at the wheel hub then undo the spline bolts to withdraw the driveshaft from the gearbox. You can then remove the driveshaft cup with a puller and replace the seal

[Alexc]

Fantastic, thank you

[Alexc]

Alex, sorry just for clarity, when you say undo the driveshaft at wheel hub, do you mean that undoing the nut at the wheel hub will be enough to pull the shaft free when I’ve undone the 6 splined bolts at the gearbox end, I.e no need to free the wheel hub assembly at all?

[alexperkins]

Correct. Once the splined bolts are removed and the CV joint released from the gearbox cup you can withdraw the driveshaft from the hub

[Alexc]

Thanks again.