Leaky gearbox?

[overdrive]

My 8 valve's gearbox seems to be leaking from the end. It looks like its coming from the pressed steel end-cap thingy. How are these fixed in? I take it they pop off in the same way as a hub-bolt cover?
Also, is this a pain in the hole to fix? Is it a common fault? Is it expensive?

Cheers in advance for the advice guys!

[jezza16v]

Yes, they just press in. I think 5th gear lives behind here. Not heard of it as a common fault though. I guess someone has been in there to sort or change the 5th gear ratio.

[overdrive]

It has been out of the car, i bought it as a second hand box so theres a fair chance there has been a knock at some point. If i pop it out is there some sort of sealant that will work against box oil to help seal it?

[DarnPB]

It has been out of the car, i bought it as a second hand box so theres a fair chance there has been a knock at some point. If i pop it out is there some sort of sealant that will work against box oil to help seal it?

It does indeed house the 5th gear. To remove the cap, you will need to drain the gearbox, then lower the engine so that you can gain access to to bolts that hold the end cap on through the left hand wheel well. Not a bad job, but make sure you have a decent gasket to fit there before you start the job.

[jezza16v]

If its just leaking around the 'green' cap I don't think you need to undo any bolts but I guess you'd have to drain the oil below this level and get it good and clean before you take it off and apply any sealer. I guess you should get a new green cap as I doubt it would come out without some distortion......Not sure what sealer you'd use though, I dont think they have sealer as standard just a tight interference fit.

[overdrive]

I have a pretty good feeling its just the wee cap at the very end of the box. Man, had that box in and out that lowering it a touch to take the 5th gear part off could be done with my eyes shut, haha. Will hit euro car parts and try fitting a new end cap first and see how that fares... cheers for the advice so far..... {columbo tone} ....but theres just one more thing.....{/columbo tone}

Any tips on getting the pressed cap out? I'm guessing hammer and chisel..

[jezza16v]

Yes, probably but don't get the chisel near the soft alloy casing, you'll probably have to punch a hole in it to wrench it out. Not sure what's directly behind it though? Make sure you can get a new one first though.

PS, I've never done this myself BTW just read about it somewhere. I think GSF do the part, called a thrust bearing cover I think?

[e11ie]

You have to take that cap off to replace the release bearing so lthat could be why its been removed. Mine leaked when I had mine replaced because the mechanic used the same cap. As a part time fix I glooped a load of silicone gasket round it and brought a new cap from VW...wasnt expensive at all.

They're not very deep so shoudnt be too much of a battle to get them off 

[overdrive]

Sweet. Gonna go get the parts now. Cheers for the help gents, will let you know how it goes!