198001991 - X015 GEARBOX/DIFFERENTIAL OIL LEAKS

An oil leak can be seen from the gearbox/differential
0PRELIMINARY CHECKSAll OKProblems encounteredOperation
Check whether the fault is accompanied by gearbox noise with the vehicle parked and in neutral.Check the gearbox/differential oil level    Op. 0010T41 MANUAL GEARBOX OIL CHECK LEVEL AND TOP UP IF NECESSARY Move on to Step 11. Noise detected from gearbox2. Oil level not correctProceed as instructed    See table S022 GEARBOX NOISE - IN NEUTRAL2. Restore the correct level and carry out a road test.    Op. 0010T41 MANUAL GEARBOX OIL CHECK LEVEL AND TOP UP IF NECESSARY If the fault persists, move on to Step 1
1CHECK FOR LEAKSAll OKProblems encounteredOperation
Wash the gearbox thoroughly, spread with talc and carry out a road test.Check that there are no leaks.In particular, check the condition of the gaskets:- gear input shaft seal;- rear cover gasket;- differential oil sealMove on to Step 21. Leaks from gaskets2. Leaks from left differential flange3. Leaks from right differential oil seal1. Replace the gaskets2. Replace the flange    Op. 2110D52 FLANGE ON DIFFERENTIAL - R.R WITH DRIVESHAFT REMOVED 3. Replace the oil seal    Op. 2110D63 RIGHT DIFFERENTIAL SHAFT OIL SEAL - R.R
2GEAR CASING CHECKAll OKProblems encounteredOperation
For 1.9 JTD 8v versionsUse talc to check visually that the gear casing is intactEnd of diagnosisCasing damaged, with presence of cracks or deformitiesReplace the gear casing, rear cover or entire gearbox    Op. 2110B32 MANUAL GEARBOX (5 SPEED) WITH DIFFERENTIAL - DISMANTLING AND REASSEMBLY - WASH AND CHECK PARTS - REPLACE SYNCHRONISERS, INNER CONTROLS, GEARS, SHAFTS AND BEARINGS
2GEAR CASING CHECKAll OKProblems encounteredOperation
For 1.4 16v 1.9 JTD 16v versionsUse talc to check visually that the gear casing is intactEnd of diagnosisCasing damaged, with presence of cracks or deformitiesReplace the gear casing, rear cover or entire gearbox    Op. 2110B26 MANUAL GEARBOX (6 SPEED) WITH DIFFERENTIAL - DISMANTLE AND REASSEMBLE, WASH AND CHECK PARTS - REPLACE SYNCHRONIZERS AND INTERNAL PARTS IF NECESSARY