Doof 11 Posted June 20, 2007 Ok I bought a gearbox that has apparently been rebuilt recently and stuck it on my car. Finally got round to filling it with oil today and the thing leaks...I was meant to be driving round Europe on monday for 3 weeks including a day or two at the nurburgring, so much for that idea!! Anyway, what do i do? Its leaking from the diff area and as far as I can see the 'box has to come off. You can see in the pic that someones gone mad with sealant but unfortunately this hasn't worked. Also you can see part of the box has snapped off where the thread of the bolt finishes, interestingly there was another hole in the top of the bellhousing but figured it was small enough not to matter. Do i: 1 take the box out and seal it up? 2 take the box out and stick the internals into my old housing? 3 Throw it all in the bin and buy a DC2 'teg? 4 Slit my wrists and jump into a vat of custard? I'm gonna just sit and cry for a bit, words can't express how pissed off i am. Share this post Link to post Share on other sites
jim21070 2 Posted June 20, 2007 (edited) Dry those eyes Doof, I know exactly how you feel, I'm an Activa owner. It is not as bad as it seems though... If the 'box performs reasonably OK, I'd go for option 2. It is not as difficult as it sounds. Option 1 may not work for reasons below and options 3 and 4 are just too horrible to contemplate!!! I say this as it looks like an unsuccessful attempt has been made to repair cracks and one wonders just what other horrors lurk within. To me it looks like a bit of the casting is missing completely as I can never recall ever seeing a part of the flywheel exposed like it appears to be in your picture. Depending on what was wrong with your old 'box, you may just get away with swapping over the first and second line gearsets and not have to worry about the 'diff and resetting its preload. Edited June 20, 2007 by jim21070 Share this post Link to post Share on other sites
jim21070 2 Posted June 20, 2007 Doof, If it is just the speedo drive housing leaking, you can swap this (to get you going) very easily and you'll not need to take the 'box off. There is a big "O" ring on the housing and I'll bet this is missing in yours. I'd still strip and check it when time permits but that'll get you going. A bit of chemical metal will seal the end of the broken thread. Share this post Link to post Share on other sites
Doof 11 Posted June 20, 2007 thanks for the replies Jim, where exactly is this O ring? Is it in the hole where the speedo cable goes? Share this post Link to post Share on other sites
jim21070 2 Posted June 20, 2007 where exactly is this O ring? Is it in the hole where the speedo cable goes? On the joint between the diff case proper and the speedo drive housing. It is about 2 and a half inches in diamater. Undo the three bolts that hold the speedo housing to the diff case and pull gently, the ring will then be seen. Share this post Link to post Share on other sites
Miles 331 1 Cars Posted June 20, 2007 It looks like the diff bolt has been tightened up too much and cracked the main box casing which make that case U/S I'm afraid but the pic might be telling lie's, Share this post Link to post Share on other sites
mi16nut 0 Posted June 21, 2007 If you can change th box again in time, give GT Gearboxes a call. He's in Bakersfield so not far from you & a good lad. He recently changed my final drive by stripping 2 boxes & rebuilding 1 for £80 the afternoon before he went on holiday. Mark. Share this post Link to post Share on other sites
Doof 11 Posted June 26, 2007 Am i being stupid by thinking about wacking a load of chemical metal around where its leaking? Share this post Link to post Share on other sites
Richie-Van-GTi 74 2 Cars Posted June 26, 2007 Am i being stupid by thinking about wacking a load of chemical metal around where its leaking? yes if you intend to travel long distance, you may end up stuck a long way from home with totally fubar g/box. Share this post Link to post Share on other sites
Doof 11 Posted June 26, 2007 Aww crap, here we go then, its gonna be a long day today i think!!!!! Share this post Link to post Share on other sites
Doof 11 Posted June 26, 2007 Hi, my name's Lewis and I'm a mong! The bolts holding the speedo housing on were bloody loose, well not hugely but i got at least a turn on them with a spanner and the leak seems to have stopped!!!!!!!! I'm so stupid!! The only worrying thing is the cracked off bit of thread and the hole in the housing at the top. I'm gonna try and fix it up so i can drive it tonight then go out and give it some serious thrashing to test things out. Share this post Link to post Share on other sites
jim21070 2 Posted June 26, 2007 Hi, my name's Lewis and I'm a mong! Been there, done that, got the T-shirt... It's called being an utterly normal person or when you reach my age, it's called a senior moment Good result Lewis. A bit of chemical metal on the broken end of the threaded hole will be fine for now. Just make sure it is very well de-greased and it'll stick like the old proverbial. Don't use too much or you may never get that bolt out again.... Share this post Link to post Share on other sites
