clubstylus

Just been running the stylus up nice and hot and running it around a little. I have noticed that it is dropping some gearbox oil though. Its coming from between the box and the bell housing, so out the front of the box. A new gasket and seal was fitted when i did the hydraulic clutch conversion, so all should be fine. No leaks are coming from the cover that i can tell and its all sealed up anyway.

Only last thing is, is that i have too much oil in the box. When i filled it, i had to put it in via the cover and visually check the level as i cant get to the filler plug. It should be level with the bottom of the plug.

Reading on a few forums, some recommend putting less in and this isnwhat Ford did on the later boxes to overcome issues.

Anyone else had oil leak problems and if so how much oil do you now use? 1.25L seems to be what is recommended.

Really dont want to take the engine and box out again this year!

Thanks

Matt

Same issue. Box leaked from input shaft from new (ie from BGH). Have changed oil seal again and still leaking. However a few drops go a long way! And never seem to need topping up ! I check annually. Rear diff does same. 1.25 litres sounds right to me. Seem to remember only getting just over 1 litre in after draining for seal change.

I use 1.6 lts which doesn't come up to the plug hole. Did you clean the threads out dry where the small capheads go into the box ? They will leak if not dry clean then thread sealed at correct torque because the thread holes aren't dead ended , they go into the box and therefore oil access --- been there done that . If you put in too much or the 1.9lts that's normally stated , you'll get cavitation , so air where oil should be under load.

There have been a few drops, but have never really driven it so thats what worries me!

Bolts were put in with Loctite 243 and degreased etc before. Will check the breather hole too to ensure that box is not being presurised and therefore blowing out the seals etc.

Sounds like i have too much in there anyway, so will suck some out and see what it does!

Thanks

Matt

I enlarged the breather hole by forcing a sharpened punch in and turning the top around very widely. Then having dried the top around the hole of any grease(petrol first)bonded a plastic syringe cut off to 50mm's , leaving the needle end on. That gave it an area to pressure oil out but run back in ----- never had a problem since. If you PM me your email address I'll send photos .
I think the pics are on here somewhere , just can't re-call which post area

Sent!

Removed the cover last night. The oil level looks to be just below the filler plug, so all good in that respect. However the breather hole was blocked up with paint, hence it has most likely been pressurising the box and hence blowing the oil out the seals!

Hopefully should stop the leaks now!

That tiny hole is totally inadequate , causes lots of problems when in a kit car at 2000 rpm higher than it's original donor ever gets. It's tricky if still in the car but with the lid out , just drill the hole to 2mm's then clean and dry around the hole and fit/sikaflex/bond etc a short tube over the hole , say 15 or 20mm diameter and 40mm's high . Seal the top of the tube then drill a 2mm hole in that. This way any oil blowing out can run back in later --- keeps it all nice and clean.

guess I better take it back off again then and open it out more!

This car will go on the road this year, even if it kills me!!