Reduction Gear Housing Leaks

edgy · Posted: Fri Aug 22, 2003 3:54 pm Post subject: Reduction Gear Housing Leaks

I still have trouble with the gear reduction unit oil leaking out the brake back plate. Seals and gaskets have been changed. Transaxle was a rebuilt unit. What am I overlooking?

hazetguy · Posted: Fri Aug 22, 2003 6:18 pm Post subject:

more info needed!
is it an early or late box (36mm or 46mm axle nut)?
did you replace the paper gasket behind the backing plate?
did you use the big o-ring in the kit (you DO NOT use that on a BUS!)?
did you replace the small o-ring on the stub axle, under the spacer?
did you torque the brake drum/axle nut before adding gear oil?
if a later box, is it leaking from the freeze plug on the back of the housing? is your bearing cover torqued to the proper spec?
is your reduction box housing cracked where the bearing cover mounts? was the place for the paper gaskets on the backing plaet (both front and back of the plate) immaculately clean before sealing the gasket?
do you have all the parts installed correctly?
if you put a new seal in the bearing cover, did it tear going in due to gouges in the housing (caused by poor removal methods) and was it lubricated with a bit of oil before the spacer was installed?
is your spacer scored with a groove, not allowing the seal to seal correcly or tearing the edge of the seal?
did the spring pop out of the seal when you put the spacer in?
if an early box, was the thick metal spacer placed in before the seal into the cover?
if an early box, did you put the thin metal washer between the bearing and the o-ring on the stub axle?
was the sealing surface of the bearing cover clean and smooth (no gouges in the metal) before assembly?
was the drain hole in the bearing cover clean and open, not full of rusty crud?

i can't think of any more right now, but these are all things i have encountered when trying to fix a leak on reduction boxes.
_________________
thebucket: I invested in hoodride, now DBD won't return my call?
hazetguy: invested?
thebucket: Yeah Haze, its where people put money into a company in hopes of a return on their money

j.pickens · Posted: Fri Aug 22, 2003 6:42 pm Post subject:

if you put a new seal in the bearing cover, did it tear going in due to gouges in the housing (caused by poor removal methods) and was it lubricated with a bit of oil before the spacer was installed?
is your spacer scored with a groove, not allowing the seal to seal correcly or tearing the edge of the seal?

One of these two was the problem with mine.
Weeping out the weep hole.

Turned out that the surface that the seal rides on is grooved.
Need to get a new one.
_________________
Founder and Chairman Emeritus, ECMSAS
BBX BBXII and BBXXI Long Distance Award Winner

edgy · Posted: Sat Aug 23, 2003 10:10 am Post subject:

36 mm axle nuit. All gaskets mentioned were replaced. Bearing cover was not torqued. What is spec?

There was no washer between the bearing and the small o-ring. I bought the truck disassembled. Do you know where I can get one?

Did not use large o-ring, no groove for it. I cannot see any cracks in housing. Oil seems to be leaking thru drain hole in back plate implying it is going past the seal. Oil is not getting on brakes. Seal was not torn and spring was in place.

Spacer may have had a groove in it, I don't recall. Where can I get new one? It has to be something like that.

I am using 80W90 oil. Should it be thicker? I have threatened to use gun grease or STP. Truck is not driven much.

j.pickens · Posted: Sat Aug 23, 2003 1:45 pm Post subject:

A buddy of mine switched to 125W tranny oil, and his weeping went away.
I may try this myself.
_________________
Founder and Chairman Emeritus, ECMSAS
BBX BBXII and BBXXI Long Distance Award Winner

hazetguy · Posted: Sat Aug 23, 2003 1:55 pm Post subject:

bearing cover torque: 55-60Nm, or 40-43 ft.lbs
washer for between bearing and small o-ring comes in the gasket seal kit.
sounds like you need to get the metal washer, use a new o-ring, check the spacer for a groove (poor sealing surface), and torque the axle nut before adding oil (this squeezes the o-ring, making the seal before oil has the chance to seep around it).
you can get new spacers through the vw dealer (not cheap, about $20), or usually you can find good ones at shows for cheap.
also make sure the seal is fully seated (squarely) in the housing. is the thick metal washer in front of the seal? the service manual has a very nice exploded view of what should be in there. if you need a copy of the pic, let me know, i'll post it to the gallery.
the oil you are using is fine. oh yeah, did you overfill the reduction boxes? this too will cause a leak. you're only to put .5 pint in them, not all the way full.
_________________
thebucket: I invested in hoodride, now DBD won't return my call?
hazetguy: invested?
thebucket: Yeah Haze, its where people put money into a company in hopes of a return on their money

edgy · Posted: Sat Aug 23, 2003 6:57 pm Post subject:

Thanks for the help. I put in 250 ccs per my shop manual. If you could post a picture, I'd appreciate it. The book I have came with the truck and does not show he washer you are talking about. It is in British English so I have to translate it. Amazing how we don't speak the same language!

Friedpotatoes · Posted: Sat Aug 23, 2003 8:26 pm Post subject:

everytime i do those seals on the backing plates i put clicone sealer on it make hell of a diffrence beed gasket beed both side never have had a leak

hazetguy · Posted: Sat Aug 23, 2003 8:28 pm Post subject:

edgy, the pic is posted:
https://www.thesamba.com/vw/gallery/pix/106101.jpg
notice how it does not show the paper gasket behind the backing plate. i consulted a later service book, and it DOES show another gasket behind the backing plate, probably an upgrade because the service guys got sick of sealing leaks from metal to metal contact. i have always used one in front and one in back, with gasket sealer (NOT SILICONE!!! sorry, but i HATE using silicone on critical tolerance stuff, well most anything for that matter) on them.
anyway, the metal washer i am talking about is #10, between the #9 oil seal and the #11 bearing cover. this is essentially an oil slinger, and i also (presume) that it helps exert the pressure to the #8 outer spacer to help seal the #7 gasket. it's about 2mm thick, and MUST be installed prior to the seal being pressed in the #11 bearing cover. otherwise you must remove the seal to put it in if you forgot it, and that sucks because you destroy the seal getting it out!
also VERY essential to this all is the #4 inner spacer.
anyway, since you said you got this in a box, you may be missing a piece or two. drop me an email (link on pic) if you need something, i think i have extras of most everyting.
_________________
thebucket: I invested in hoodride, now DBD won't return my call?
hazetguy: invested?
thebucket: Yeah Haze, its where people put money into a company in hopes of a return on their money

Friedpotatoes · Posted: Sat Aug 23, 2003 8:28 pm Post subject:

on all tranny seals i do that well the ones i can


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