FL1 TD4 Facelift Gearbox Covered In Soot!?

Hi guys!

hoping someone can shed some light, looking under the car I noticed some sort of oil and a lot of soot all over the gearbox. Haven’t really got any issues with the gearbox (serviced last month) it’s a manual getreg, have done a lot of repairs in the past month. Only issue now is getting awful mpg, no smoke. Just wondering if it’s linked to this suspicious soot? Also some oil from the hose which I think is turbo to intercooler?

Looks like the battery side intercooler hose has blown or the clip is loose. Check the s shaped one and the short elbow and you'll probs find it is all black and sticky.
This will reduce the boost pressure, screw the performance and the mpg.

Its probably the intercooler hose, but the 'soot' isn't the sound deadening material under the bonnet perrishing by any chance?

Elbow hose from the egr was replaced not too long ago, I’ll take that intercooler one off and check it/give it a clean, probs duct tape until a new one arrives Hmm not sure about the sound material, I’ll have a look, I was wondering if the exhaust was blowing as at around 30mph with the window down there is a slight noise similar to paper on fan if that makes sense? I’m also aware the drivers drive shaft needs replacing, got a replacement waiting to go on

Hippolady26 said:

Elbow hose from the egr was replaced not too long ago, I’ll take that intercooler one off and check it/give it a clean, probs duct tape until a new one arrives Hmm not sure about the sound material, I’ll have a look, I was wondering if the exhaust was blowing as at around 30mph with the window down there is a slight noise similar to paper on fan if that makes sense? I’m also aware the drivers drive shaft needs replacing, got a replacement waiting to go on

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Depending on what's wrong with the old one, you should get the replacement drive shaft installed ASAP - if its the inner CV where the fault is, this can take out its support bearing in the IRD and then you are in for a whole heap of pain.

Not entirely sure, replaced the passenger side a few weeks ago, but by the time I’d done that one I was knackered, the nut on the drivers side was seized and that shaft wasn’t making a noise, it’s now got play where I can move it back and forth slightly, rattles when turning so possibly the inner cv, the prop shaft is currently off so will it still affect the ird?

Hippolady26 said:

Not entirely sure, replaced the passenger side a few weeks ago, but by the time I’d done that one I was knackered, the nut on the drivers side was seized and that shaft wasn’t making a noise, it’s now got play where I can move it back and forth slightly, rattles when turning so possibly the inner cv, the prop shaft is currently off so will it still affect the ird?

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Yeh, if the inner CV is shot it will eventually damage its support bearing and this can jam the IRD and actually crack the case. That's regardless of whether its 2 or 4 wheel drive.

Ouch! I didn’t know that so thank you! I’ll get it done this weekend, if it is the inner cv, do you reckon that oil on the bell housing is possibly cv grease? Or is it too far away?

Hippolady26 said:

Not entirely sure, replaced the passenger side a few weeks ago, but by the time I’d done that one I was knackered, the nut on the drivers side was seized and that shaft wasn’t making a noise, it’s now got play where I can move it back and forth slightly, rattles when turning so possibly the inner cv, the prop shaft is currently off so will it still affect the ird?

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The hub nuts are a real tight and a bugger to get off.

I have put a long extension pole over a breaker bar and not shifted the nut, in the end I used a shorter pole with a jack under it and lifted it with that - I'm not sure how safe that is though because if something slips there's a lot of tension in there and poles could start flying around and take you out!

I've also hear of people putting extension poles on a breaker bar and moving the car under power to shift them - once again, not sure how safe this is!

Hippolady26 said:

Ouch! I didn’t know that so thank you! I’ll get it done this weekend, if it is the inner cv, do you reckon that oil on the bell housing is possibly cv grease? Or is it too far away?

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I wouldn't think grease from a drivers side CV could end up on the top of the bell housing - especially if there are no signs of it between the 2.

Managed to get the passenger side off, it’s been soaked in plus gas for a few weeks now so hopefully should be able to get it off the car hasn’t been well looked after previously so everything is rusty and difficult (bit like myself) it’s become part a labour of love and part pure hell but I’m in too deep now so it’s getting fully refurbed

Ah ok fair enough, my other thought was possibly the fuel rail pressure sensor leaking as I did read a post online where someone had the same leak and it was that, I’ll have a cuppa and go investigate I suppose

So had a poke about underneath seems the oil is coming from this join but can’t work out if it’s the join between the gearbox and ird or the oil sump, towards the front end there’s a lot of oil covering the starter motor etc

Did you have a look if the propshaft gaiter is still intact?

mbrokof said:

Did you have a look if the propshaft gaiter is still intact?

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no idea what that even looks like however I think I’ve found the source of the leak, noticed the fuel hoses in the engine were really cracked… so have removed, and replaced, I’ve cleaned away as much of the oil as possible and we’ll see if that’s solved it

Hippolady26 said:

So had a poke about underneath seems the oil is coming from this join but can’t work out if it’s the join between the gearbox and ird or the oil sump, towards the front end there’s a lot of oil covering the starter motor etc

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It's possibly from the O ring that seals the IRD to the gearbox.

Hippolady26 said:

no idea what that even looks like however I think I’ve found the source of the leak, noticed the fuel hoses in the engine were really cracked… so have removed, and replaced, I’ve cleaned away as much of the oil as possible and we’ll see if that’s solved it

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Looks like that one here :TVB000090GTR Gaiter Kit Fl1 Propshaft Front (advancedfactors.co.uk)

Ah ok no that’s not there, the metal part is but not the rubber boot

Hippolady26 said:

Ah ok no that’s not there, the metal part is but not the rubber boot

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When you say the metal part is there but not the rubber boot, from that metal part is there a prop shaft running to the back diff?

No full prop is removed as the vcu was starting to seize, I’m sending that off to Bell when I get chance, but have been fixing many other faults in the meantime so far I’ve replaced lower suspension arms, track rod ends, front drive shafts, hp pump regulator, low pressure pump and filter, full service, brakes all round and 4 new tyres. The LP pump does make quite an annoying high pitched noise though, I replaced the failed one with a Pierburg but still noisy also had a new heated windscreen, window regs, crankcase upgrade and new hoses…. I love this car but she’s wearing me out!