well after refilling gearbox that i just refitted realise it leaks which explains lack of oil, now after looking at guides & doing a search realise not much info available so if i get some replies ill do a guide on seal replacement i think its output shaft seal??? thats gone so gearbox out again!

Got this picture on eper, best I could find - number 8 is the only seal

In fact, found this:



It's the main shaft of the gearbox, the counter shaft and the other shaft (just named "shaft" on eper) had no seals listed. Number 3 is the seal. Hope this helps anyway man

number 6 i was thinking? mine not 115 btw

The diagrams above are different gearboxes. Posts #2 and #3 is a JTD 115bhp gearbox. Post #4 is a JTD 80bhp gearbox. The input shaft oils seals are different for each gearbox.

where abouts is the oil leaking from, is it coming from within the box (remove the flywheel inspection plate and look for oil inside) or is it on the outside of the box?
if its on the outside then there is a liquid gasket, you effectively need to strip the box down and remove the old gasket, then apply new liquid gasket to the same area. Don't be coy with the amounts of gasket sealer, apply loads as any gaps will allow oil to escape again.
Either way the box has to come of and i would also replace the clutch and shaft seal.
if i was in your shoes i would just top the box up regularly until the clutch needs to be changed, then hit it all in one go. Major job and not for the feint hearted tbh

Thanks roy,oil is coming out of join between cyl block & bellhousing. Clutch has just been done I put gearbox back in last week didn't cross my mind to replace seal.think it shaft seal that's gone. Also oil p*ssing out its a heavy leak gonna do job next weekend

Is it definately gearbox oil and not engine oil from the rear main oil seal? Would have thought a leak from the gearbox input shaft seal would have been obvious when you had the gearbox out.

I replaced my JTD 115bhp clutch, dual mass flywheel and concentric slave cylinder last week. There was no leak from the gearbox oil seal, but there was from the rear main. That leak wasn't obvious until I removed the DMF. Fortunately, I'd bought all the seals just in case they were needed.

Yeah I think its gearbox oil because its clear(engine oil black) only leaked when it had been filled, only put gearbox in when I bought car as gearbox was out already and had been out a few months,was advised to put oil in geartbox as well which leads me to belive its an old leak, thanks davren mines the 80 bhp one by the way,so do you think I should get rear main oil seal AND gearbox one as well? Am only 2 mile from a fiat dealer

If you're sure it's gearbox oil, then it's likely to be just the gearbox oil seal that's needed.

Rear engine oil seal is about £50 from Fiat. It comes complete the the engine rear cover and plastic guide ring tool to fit it over the crankshaft.
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EDIT: Just had a thought. Not sure if there's a breather inside the gearbox bell housing. Could you have over filled it? If so oil may be getting forced out of the breather. Check the oil level at the level plug with the car on flat ground.

Ok davren it took 1.5 litres ish to start coming out of fill\level plug orderd seal at fiat £6.59 inc vat pretty sure it G\box oil stop and it drips there's now 3 patches outside work lol

saw said:

pretty sure it G\box oil stop and it drips there's now 3 patches outside work lol

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You can smell it. Gearbox oil has a very pungent smell.

Davren said:

You can smell it. Gearbox oil has a very pungent smell.

Click to expand...

aye but synth smells different to mineral oil, would dropping engine and box be easier than just dropping box? got oil seal also found out FIAT dealer is cheaper for oil than halfrauds just waiting to find out about engine hoist so i can sort this out at weekend

I used Fiat Tutela ZC 75/85 Synth when I changed my gearbox oil a few years ago, and Tutela Matryx 75/85 Synth (the replacement for ZC 75/85) when I refilled the box after fitting a new clutch and flywheel a few weeks ago. They both smelt like conventional gearbox oil. Perhaps they put a stenching agent in it so you can tell what it is.

My gearbox came out easily but was a pain getting it back in. Possibly because I was doing it alone and it was difficult lifting and aligning it alone. I ended up making an "A" frame and lifting it with a ratchet strap. I never even considered taking the engine and box out together. Too much to disconnect and drain. (Cooling system, air conditioning system, vacuum pipes etc. and every electrical connector on the engine).
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thing is davren i put G/box back in so know its a pain with engine in (starter bolts for instance?) also thinking about dropping hub & driveshaft out for a bit more room to move cos i try and find ways to make the job easier for me, must remember to sweep the barn out as well.also i would clean elec connections if engine was out i got no a/c either and im on my own as well and wish i had the 115 cos there's room under there lol

Well there you go... you've answered your own question.

Room under the 115 as opposed to what?

Looks like u got more room under the bonnet but probably an illusion

My picture is with the battery, battery box, engine fuse box, air filter housing, air pipes, fuel filter etc. removed. You'd have to do most of that to take the engine and box out anyway.

Re: Gearbox Oil Change

after getting car on ramps i found 3 plugs the one at the back of the diff i had to scrape crud out of...... soooo have i over filled? does seal need replaced? am thinking just cart on and do seal anyway (cos i borrowed engine hoist) as this would eliminate future probs and refill G/box using correct level plug this time :bang:

Re: Gearbox Oil Change

i think output shaft (splined one that goes through clutch) seal is the one that leaks,as it only leaked after filling with oil using filler plug as level plug,so you see the quandry? As fill plug different to level plug so don't know if I overfilled hence leak or seal u/s.I dunno but doing seal anyway