Outer Limits 4x4 Board

Hi all,
I have a 1991 2.8 turbo diesel rocky here in australia (fourtrak in UK)
I have a pretty bad oil leak coming from between motor and gearbox so i pulled the gearbox off assuming that the rear main seal would be the issue.

Seems as though I am correct but i don't know how to get the seal off and how to install the new one?
If you look at the picture below, it seems to be sitting in a alloy housing. the alloy housing looks removeable but i removed all the bolts around the housing and the ones underneath coming through the sump and into the housing and it didn't seem to make a difference. seems as tbhough there's also bolts going into the alloy housing from inside the motor??

Can anyone help me with this?

are there no bolts going through from the sump into said housing? Thats how the H series (Petrol engines) are - you actually have to drop the sump to get at them. Could be a similar setup in the diesel...

Yeah there are 4 sump bolts that go into the housing ... i removed them but still didn't seem to get any movement or any signs of the housing coming off.

Really hoping that i don't have to drop the sump

bexi wrote:Yeah there are 4 sump bolts that go into the housing ... i removed them but still didn't seem to get any movement or any signs of the housing coming off.

Really hoping that i don't have to drop the sump

Replacing the bead of sealant around the sump probably wouldn't be a bad thing though mate!

Yeah i know ... it's just such painful job scraping all the old stuff off the sump and block :(

bexi wrote:Yeah i know ... it's just such painful job scraping all the old stuff off the sump and block :(

Hmmmm - on the HD's I've build up, its never taken any longer than a few minutes with a razor blade - the hardest part is making sure you don't get too much crap in the pan...

Yeah i just did one on a hd (applause motor into feroza) ... definitely took alot longer than a few minutes

Ok so this reply is for anyone who needs to do this in the future ...

... you may disagree with what i've just done but here it is... (It is a huge time saver)



Got the seal out very easily ... just drilled two tiny holes in the face of the seal then screwed the 2 screws into the seal and pulled on the screws carefully with pliers levering on the crankshaft flange that the flywheel bolts to.

My plan is to buy a new biton seal and cover it in rubber grease and attempt to gently install.

The only disturbing thing is that i can't start the car to test if the leak is fixed until i reinstall the gearbox and starter motor!

How do you intend on re-installing the gearbox?

Mines on the garage floor, deemed 'too hard'. Any tips for manhandling it into place - with the car on the ground held slightly up by jackstands.

I have access to a hoist, but its a trip on the back of a tilt tray that I really can't justify paying for at the moment.

I've an engine lift, through the passenger door holding up the gearbox through the shifter hole in the tunnel. I can get the gearbox up, at what seems to be the right angle, but it just wont slot into place. Any tips?

Well i think i'll be at that stage on the weekend (ready to put the box back in)

I have a big 2 tonne floor jack sitting under the gearbox cross member that the gearbox is sitting on.

I intend to have myself and a mate guiding gearbox while another mate operates the jack

I have the car on ramps at the back and axle stnds on the front.

The hardest part might be getting those gearbox bolts in the top of the bell housing .... there's stuff all space!

With the engine tipped back (Gearbox down and resting on jack) there should be plenty of room if you use about 45 foot worth of extensions... I was even able to use the rattle gun on said extensions!

You're more than welcome to help put mine back in when you're finished...its being a dead set prick!

Yeah i used many different length extensions and rattle gun to undo the bolts.

I just noticed you're from nowra which is funny because that's where I just bought this one from!

bexi wrote:Yeah i used many different length extensions and rattle gun to undo the bolts.

I just noticed you're from nowra which is funny because that's where I just bought this one from!

I got mine from Western Sydney...

Well - I shoved the gearbox in this evening...

I had a few different mates come over and we attempted to get it in over the weekend to no avail. They all suggested either getting a transmission jack, or a trailer ride into my mates workshop with hoist.

Well farkem I said today, and got it in. No help from others - it really wasn't that hard...so you should manage with your mates this weekend mate!