Gearbox drain

[KennyW]

Hi All,

Just found a crack at my gearbox drain hole. This explains the problem I had in loosening the plug as it appears when the clutch was done (before I owned the car) some body has tightened the plug with impact wrench.The copper washer was almost gone and the thread on the plug was partially rounded.

I'm going to use JB Weld epoxy to fill in crack allow it to cure and try to seal it. Otherwise The car will have to be scrapped. I'm not going to remove gearbox and fix it.

It is not worth the effort,time and money.

I'll post up the out come soon.

Kenny

[GiveMeABreak]

Damn, sorry to hear that Kenny, people think those impact wrenches / Air guns are the answer to everything - clearly not...

[Sloppysod]

Kenny, i don't know the location of the drainplug, but have you considered a Helicoil insert. basically the thread is retapped to a slightly larger thread, then metal insert is screwed into the hole and your original or new drainplug is fitted.
I'm making an assumption here, but if the thread on the plug is M12 then a kit like this would do and problem fixed for good.

I'm sure someone will be be able to help identify the threads ze and feasibility.

https://www.ebay.co.uk/itm/262718425818 ... media=COPY

https://youtu.be/zAXVvhpnuUU?si=dNA-PKp-yv3PuDtx

[KennyW]

Thanks for the replies,

The crack runs from the inside of the hole along the mating surface to the outside so the oil follows this and slowly drips out. So a threaded insert won't work. Hence using the epoxy to fill the crack and hopefully stop this leak. I used a M16 tap to check the thread and all is fine. I have a new drain plug and copper seal ready.

Will report back later.

Kenny

[MattBLancs]

How annoying and disappointing!

I've done the clutch (well the clutch slave cylinder) on my 2.2, it is a fair old job. Can do it on your own with an engine crane but lots to remove to get to removing the box.

(Versus scrapping the car) I'd be tempted to put some PTFE tape on the plug's threads too, every little helps!

[Sloppysod]

okay Kenny, another tip, I've been using a spray degreaser made by the people who make WD40. good stuff.
https://www.toolstation.com/wd-40-speci ... ser/p20321

[KennyW]

Thanks for the replies,

I've got RTV silicone black sealer which can be used on the oil sump. Going out to sand down the epoxy and see what happens.

Kenny

[KennyW]

Update, JB Weld did not work, the crack is far worse than originally thought.

It runs halfway up the inside of the hole along the mating surface and up the outside of the hole.

I have no option but to scrap the vehicle.

Kenny

[MattBLancs]

Sorry to hear that, how frustrating

[Paul-R]

Which vehicle is/was this?

[Sloppysod]

it's a shame, another car scrapped due to heavy handed gorillas.
Not sure if its still available, but a product called "Petro-Patch" may have been able to help, its basically a oil resistant fibreglass... cover the whole area?

[KennyW]

Paul Its the C5

Stu, The biggest problem is access. The gearbox drain plug doesn't even have an access hole in the sub-frame. It can be fixed but requires the gearbox to be removed then either the welded difficult or replace the casing only. A second hand gearbox could be fitted but history is unknown. If the gearbox is off, I would change the clutch. The costs are starting to mount up.
Finally I no longer have a garage to carry out the work.
Hence scrap the car but the scrap value is terrible.

Kenny

[myglaren]

Is it worth trying to sell it for 'spares or repair'?
I got eighty quid for my C5.

[KennyW]

Thought about that, going to phone around the local scrappies to get an Idea of value.

Kenny

[KennyW]

Okay a quick update, got very frustrated with leak. So cleaned up drain plug area, removed as much oil as possible, using my epoxy resin coated the drain plug and screwed it in and left it to cure for a few days.

Tuesday I partially filled gearbox with 500ml of oil an left it for 30 mins or so.

Returned later no leak.

Topped it up and used on Wednesday and checked again today no leak.

Just got the 2 other leaks to repair.

Kenny