96 Tdi ZF auto box isues

Hi all

Following Pantellis comment about the virtues of replacing the gearbox
oil several times and cleaning the filter, I thought I would have a go
this weekend.

Bought myself three gearbox oil seals from ZF (LR don't even know they
exist in my neck of the woods) only to discover they are rubber and
can probably be reused.

Then set about getting under wagon. First discovery, lots of oil
emanating from the t-case. Didn't have a good look but it seemed to be
all over. Next dicovery after removing five of the oil pan securing
thingys from the g-box, discovered no6 required removal of gearbox
mount or similar to get near the bolt.

Result, wagon going off to local work from home mechanic when I get a
chance and looks like the t case and box will be coming out.

PS I am at around 237 000km. Do you think the t case should require
much new stuff inside, or just a few seals?

Fanie Hi,

please excuse me for forgeting to advise you beforehand about having to undo
the crossmember in order to be able to remove the autobox's pan and gain
access to the filter.

Actually you do not have to completely remove it just undo two of the four
bolts securing the crossmember on the chassis and then tilt it downwards a
bit so that you can undo the bolts and remove the pan.

---------

As for the transfer box you may find that the seals are damaged. Transfer
box cases are a bit sensitive and tend to crack around the exit bearings and
seals area. I hope this is not the case with yours.

Take care
Pantelis

"fanie" <[email protected]> wrote in message
news:[email protected]...
> Hi all
>
> Following Pantellis comment about the virtues of replacing the gearbox
> oil several times and cleaning the filter, I thought I would have a go
> this weekend.
>
> Bought myself three gearbox oil seals from ZF (LR don't even know they
> exist in my neck of the woods) only to discover they are rubber and
> can probably be reused.
>
> Then set about getting under wagon. First discovery, lots of oil
> emanating from the t-case. Didn't have a good look but it seemed to be
> all over. Next dicovery after removing five of the oil pan securing
> thingys from the g-box, discovered no6 required removal of gearbox
> mount or similar to get near the bolt.
>
> Result, wagon going off to local work from home mechanic when I get a
> chance and looks like the t case and box will be coming out.
>
> PS I am at around 237 000km. Do you think the t case should require
> much new stuff inside, or just a few seals?

Thanks again

I think it will still be a job for my mechie, as the kids will not
permit enough time under wagon before wife threatens to kill me.

Regards
stephen
On Tue, 18 Apr 2006 19:13:28 +0300, "Pantelis Giamarellos"
<[email protected]> wrote:

>Fanie Hi,
>
>please excuse me for forgeting to advise you beforehand about having to undo
>the crossmember in order to be able to remove the autobox's pan and gain
>access to the filter.
>
>Actually you do not have to completely remove it just undo two of the four
>bolts securing the crossmember on the chassis and then tilt it downwards a
>bit so that you can undo the bolts and remove the pan.
>
>---------
>
>As for the transfer box you may find that the seals are damaged. Transfer
>box cases are a bit sensitive and tend to crack around the exit bearings and
>seals area. I hope this is not the case with yours.
>
>Take care
>Pantelis
>
>"fanie" <[email protected]> wrote in message
>news:[email protected]...
>> Hi all
>>
>> Following Pantellis comment about the virtues of replacing the gearbox
>> oil several times and cleaning the filter, I thought I would have a go
>> this weekend.
>>
>> Bought myself three gearbox oil seals from ZF (LR don't even know they
>> exist in my neck of the woods) only to discover they are rubber and
>> can probably be reused.
>>
>> Then set about getting under wagon. First discovery, lots of oil
>> emanating from the t-case. Didn't have a good look but it seemed to be
>> all over. Next dicovery after removing five of the oil pan securing
>> thingys from the g-box, discovered no6 required removal of gearbox
>> mount or similar to get near the bolt.
>>
>> Result, wagon going off to local work from home mechanic when I get a
>> chance and looks like the t case and box will be coming out.
>>
>> PS I am at around 237 000km. Do you think the t case should require
>> much new stuff inside, or just a few seals?
>