FL1 TD4 manual 2005 gear oil leak problem

I took of the tray beneath the engine. Here i could see oil dripping when engine was running. Seem like it's coming through the crack between gearbox and housing on the right (see image and video).

Any ideas where to go from here?

First check it is oil and not hydraulic fluid. Does the clutch pedal still operate correctly?? Looks thin and clean for oil.

If it is oil it looks more like gear oil than engine oil. Probably the gearbox input shaft seal.
Sadly if it is clutch fluid or gear oil the box has to come out.

Obvs, check it isn't from higher up and running down first!

andyfreelandy said:

First check it is oil and not hydraulic fluid. Does the clutch pedal still operate correctly?? Looks thin and clean for oil.

If it is oil it looks more like gear oil than engine oil. Probably the gearbox input shaft seal.
Sadly if it is clutch fluid or gear oil the box has to come out.

Obvs, check it isn't from higher up and running down first!

Click to expand...

Hi - thanks for feedback. I suspect this is gear oil, as the engine oil appears darker in colour. Clutch works well. Will continue to check.

Maybe to check the gear box oil level.
If i try to top it up - until it flows over, i would get an idea of it - or am i lost?

LarsB said:

Maybe to check the gear box oil level.
If i try to top it up - until it flows over, i would get an idea of it - or am i lost?

Click to expand...

There's only 3 possible sources of the fluid discounting the coolant, as suggested by Andy.

I've never seen a gearbox first motion (input) shaft seal leaking that rapidly, especially as the shaft seal is well above the bottom of the box.

Thanks for theories. I have not identified the leak source yet. I still suspect it is gear oil though.
But looking at the box in profile (image below from internet) - the input shaft is in centre, right?
And as i know this is the only gasket holding gear oil in this compartment, or am i wrong?

Do anyone know what the tube things near the shaft is?
If the leak source is the shaft gasket - what parts do i need to change? Is it smart to fit a new shaft bearing while I’m having the box out?

Just done one, it didn't leak as bad as yours but did unfortunately contaminate the clutch plates.

Tube and a small seal in the gearbox end comes as a complete unit.
Change the hydraulic slave while you are in there, they fail and leak too.
If clutch is contaminated then that will need doing too.
I think whatever the source you need to drop the gearbox out and then you will see.

Only other thought, has gearbox been overfilled?? Worth a check before you start as it is a 7 to 10 hour job!!

Good lists of tasks on this forum. Search clutch list and the user Alibro.

andyfreelandy said:

Just done one, it didn't leak as bad as yours but did unfortunately contaminate the clutch plates.

Tube and a small seal in the gearbox end comes as a complete unit.
Change the hydraulic slave while you are in there, they fail and leak too.
If clutch is contaminated then that will need doing too.
I think whatever the source you need to drop the gearbox out and then you will see.

Only other thought, has gearbox been overfilled?? Worth a check before you start as it is a 7 to 10 hour job!!

Good lists of tasks on this forum. Search clutch list and the user Alibro.

Click to expand...

Thanks again. I do not think it ever was overfilled. But after twisting my brain, with good help from this forum, i have decided to take the box out. Will write a list of parts and tools needed. (Tips and hints appreciated).
Anyone know if gear box can be lifted out from above?

No as you won't be able to separate it from engine due to the restricted width.
Alibros list is good.
If you have the space and time it is easier to drop engine, box, IRD all bolted together and then split them in my view but just to remove box it needs to come out from below like any fwd car clutch change.

Obviously prop, IRD, subframe, and driveshaft all come off then gearbox mount with engine supported, pull box off.

Good luck. It is quite heavy. I used a transmission jack when I did one but then I am working alone and don't like holding 60 or 70 Kg above my head while lining it up!!!

This lad seems pretty bad ass.
Guess i have to get hold of some lifting devices.

andyfreelandy said:

Just done one, it didn't leak as bad as yours but did unfortunately contaminate the clutch plates.

Tube and a small seal in the gearbox end comes as a complete unit.
Change the hydraulic slave while you are in there, they fail and leak too.
If clutch is contaminated then that will need doing too.
I think whatever the source you need to drop the gearbox out and then you will see.

Only other thought, has gearbox been overfilled?? Worth a check before you start as it is a 7 to 10 hour job!!

Good lists of tasks on this forum. Search clutch list and the user Alibro.

Click to expand...

Is this the tube/seal-thing? Are there any nearby bearings or seals on this side to be aware of?

That's the part. Very expensive but without measuring the seal and ordering from a seal supplier you can't buy the seal separately.

Seal is fitted on the flanged end. There is a bearing at the input end of the gearbox but you don't disturb it fitting the part.

The clutch slave cylinder slides on this part with its own hydraulic seals.

LarsB said:

Is this the tube/seal-thing? Are there any nearby bearings or seals on this side to be aware of?

Click to expand...

Fooking hell - 85 quid for that!

That's robbery.

GrumpyGel said:

Fooking hell - 85 quid for that!

That's robbery.

Click to expand...

It's cheaper from DMGRS.
https://www.dmgrs.co.uk/products/r75-mg-zt-slave-cylinder-guide-tube-input-shaft-seal-utl100081

GrumpyGel said:

Fooking hell - 85 quid for that!

That's robbery.

Click to expand...

A bit stiff allright, but i browswed arounf - and it looks like a Rover model uses the same unit. And it seems to be a bit cheaper. Part number is the same, and page says it fits certain freelanders. More than half the price.

Nodge68 said:

It's cheaper from DMGRS.
https://www.dmgrs.co.uk/products/r75-mg-zt-slave-cylinder-guide-tube-input-shaft-seal-utl100081

Click to expand...

That's a bit fairer

Time to find the replacement seals and sell them much much cheaper!!

@LarsB when you remove the input seal and shaft, please can you measure the gearbox input shaft diameter? So effectively the inside diameter of the oil seal?
I have a spare worn seal and can measure the outside diameter and thickness but I need the actual gearbox input shaft diameter.

That would be very helpful, then I can look up some replacement seals to save an £85 or even £35 bill !

Many thanks

andyfreelandy said:

@LarsB when you remove the input seal and shaft, please can you measure the gearbox input shaft diameter? So effectively the inside diameter of the oil seal?
I have a spare worn seal and can measure the outside diameter and thickness but I need the actual gearbox input shaft diameter.

That would be very helpful, then I can look up some replacement seals to save an £85 or even £35 bill !

Many thanks

Click to expand...

OK, will try do when I get there.
I am in the tool gathering phase
I was sure i saw the measures in another forum, but I can’t find it right now. Will tell if i find it.