Pulling My Hair Out

[Chooka]

I've just put a new engine in my VR4 and I'm pulling my hair out trying to find an oil leak thats develloped.:fuuuuu: I'm almost certain it's gearbox oil and that it's coming from the oil seal where the left side front drive shaft enters the gearbox. I've already replaced the oil seal once and it's still leaking. At the moment I've got the drive shaft out and the new seal appears to be in perfect condition.
I'm just wondering if anyone else has had an issue with this happening to them, and if in fact the oil seal is the source of my problems, or is there somewhere else I should be looking? I've had the car up on stands, in gear and running and it doesn't seem to leak... it only leaks while driving on the road... perhaps because the gearbox is under more load and creating more preasure?
Any help at this stage would be greatly apprieciated!

 

[bazeng]

Is it a vr4 or a galant gsr with a vr4 motor?

I'm just thinking if it has the 1 piece drive shaft or 2 piece drive shaft.

If it was the right hand side leaking, then I would say that you probably pushed the seal in too far as it seals with the cup surface also. But the left side shouldn't leak if you have pushed the shaft in all the way and bolted the 2 piece shaft in place on the block.

How did you install the seal?
Did you check the surface of the seat of the seal prior to install? Was the seal installed dry or with sealant? or with grease?

Sorry for all the questions, it justs makes things a bit clearer...

 

[VR-4Squid]

The transfer case output shaft is just below and is equally likely to be the problem.

Often the ball bearing that holds the shaft in place (viscous unit holds it in place) is missing (even with an apparently un-opened gearbox), this allows the shaft to slide across towards the transfer case (about an inch before the splines bottom out in the t-case) enough for the oil seal to not line up with the correct surface on the shaft.

It took me ages to realise that this was the problem I had.

The solution is either to pull the end casing off the gearbox, and the v/c, and fit the ball bearing - or, fit a spacer into the transfer case to prevent the shaft from sliding over.
Mine had a roll of cardboard when i first took the box off!! I replaced it with a length of wooden dowel and have had no leak's (or any other related problems) in nearly 7 years.

 

[GVR40]

it could also have a crack in the actual gearbox casing, thats where mine leaked from.

 

[bazeng]

Good idea squid!

I never liked the slop of the shaft.

Did you ever wonder what happened to the ball bearing in your box?

 

[Chooka]

Wow! Thanks for all that guys, thats a fantastic responce. It is a Galant VR4 and yeah has the two piece drive shaft. I'm fairly sure we put the seal in square and correct allthough we didn't use any sealant, only a bit of oil to help it slide in. I've looked at the shaft from the gearbox to transfer case and it seam very dry... no apparent oil. but mabey I need to inspect it further?
Where abouts was the crack in your gearbox GVR40? I haven't even inspected the casing yet. It just really seems that the oil is comming from the seal and being splatted around by the drive shaft. but why would it be leaking with the original oil seal and then again with a new one, unless I'm very unlucky... aarrghhh this is driving me nuts, i just want the damm thing back on he road!:fuuuuu:
One thing I Forgot to mention is that I overfilled the oil in the geabox. could this have damaged something?

Thanks again guys, the collective knowledge of this group is fantastice, please keep the info comming!

 

[bazeng]

Overfilling won't help, drain a bit out.

Also make sure` its not the 4ws lines leaking around the PS rack...

 

[Chooka]

yeah as soon as I realised I'd overfilled it I drained a bit out. thanks for that other suggestion I'll get under the car tomorrow and have yet another fidget around.

 

[GVR40]

mine leaked from a hairline crack just above the seal, so it looked like it was coming from the seal. it could also be the fluid from the transfer case leaking though that seal

 

[rob323]

1. How can you overfill the gearbox? The oil runs back out of the filler hole when it's at the right level.
2. Are you sure it's gearbox oil, not ps fluid or engine oil (rear main seal leak)?
3. Pull the transfer case out and make sure it's not leaking out through the inspection plate on top (I had that problem once).

 

[Chooka]

1. I jacked the car up at the front to fill the gearbox, and hence the fill hole was higher than the rear of the gearbox, and it took alot more oil before it started coming out the fill hole at the front.

2. I'm fairly sure it's gearbox oil, (smells like geaxbox oil) and the engine oil isn't going down. PS fluid level is one thing I haven't checked yet though... thats a good idea, even if it's just to cross it off the list.

3. I've got the transfer case off at the moment so I'll check that plate. I did check the oil level in the case though and it seemed full. At this stage I think it's worth double checking everything tho!

Thanks for the added info/ideas rob!

 

[rob323]

1. I jacked the car up at the front to fill the gearbox, and hence the fill hole was higher than the rear of the gearbox, and it took alot more oil before it started coming out the fill hole at the front.

That's fine. That is how I always do mine. You will be lucky to get more than a 100-200 ml extra in there in anycase.

2. I'm fairly sure it's gearbox oil, (smells like geaxbox oil) and the engine oil isn't going down. PS fluid level is one thing I haven't checked yet though... thats a good idea, even if it's just to cross it off the list.

Gearbox oil is normally clear and has a sulphur or synthetic smell, power steer oil is usually red, and engine oil is usually
black.