'there's a hole in my g/box! dear lizza dear lizza!'

Started by badhabit, October 02, 2010, 08:37:32 PM

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badhabit

'with what shall we fix it! you bastard you bastard!!!

My '03 Bora 4motion dropped it's lunch 2wks ago. Well oil anyway.
Came off the motorway and pulled up to some lights to smell a burning oil smell. I thought - 'that cant be me? this car is like brand new!!!'
Drove 200m to park in a hardware store carpark non the wiser to the odour. Came out 10mins later to see an oil slick streaming out of the front of my car!!! :-[

Car was towed home and on investigation found a pin head hole at the lowest part of the g/box casing. No other visible damage, nothing! but there did appear to be some odd rough casting marks around the area. Thought the worst that something inside was trying to get out!!!

whatever caused it had caused a very slow leak and since i had only driven it a very short distance that 95% of the oil was still in the box or now on the carpark!!

80vert was kind enough to help me pull the box out today to investigate the cause. We were both puzzled as to the reason. And what did we find.....................................

WELL!!! - who would have thought but the problem has been there since it left the factory! when they cast the casing there was an air bubble / cavity which when the case was machined for bearings etc it opened up cavity and over time whatever had blocked the hole has dislodged and all the oil of course started flowing!!.

1 in a million chance!!!! good on ya Volkswagen!!!!!!
oh so lucky not to destroy a 6speed!



2007 Honda Euro
1973 Datsun 240Z - RB25det build
1991 Porsche 911/964
1960 VW karmann ghia

RobClubley

1985 ur quattro
1992 Ford Courier - the sensible daily

Poonmobile

great that you caught it time! So all patched and set for sail?
Current:
06 NZ B7 RS4 Avus Silver, 01 NZ B5 RS4 Avus Silver, 93 NZ VR6 Tornado Red 3dr, Renault Clio 172 & Renault Clio 197
Past:
MK2 VR6, MK5 GTI, 2 x MK5 R32, 8L S3 Imola, MK4 Golf V6 4MO, Polo GTI, 2x MK3 VR6, D2 S8, B5 S4 Avant, 03 NZ R32 Deep Blue Pearl, Renault Megane R26 liquid yello

80 Vert

Nah not yet, will get the case welded next week. Case is magnesium so will have to farm it out.
2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

badhabit

Yeah luck was on my side that day!
not fixed as yet. Will have it repaired next week for install next weekend all going well.
Spreading the job across 2 days is a godsend cause it ain't a 5min job to pull the bugger out!
It will get some lovely new special oil that apparently VW suggest and all should be well once more!
2007 Honda Euro
1973 Datsun 240Z - RB25det build
1991 Porsche 911/964
1960 VW karmann ghia

BB

 Just put it back together and shove a screw in it from the outside ;)
The end is nigh, but the end of what is the question?

qta4

That may not be very easy to repair, once welded up the surface will need to be remachined to suit.
Have you spoken to VW, as it is definitely a manufactuing error.

If that was Fisher and Paykel, they would replace part, no questions asked.
Skill is, sucessfully tightrope walking across the Niagra Falls.
Intelligence is, having the sense not to do it.

80 Vert

Car is 7 years old Noel and an import, they will tell him to piss off.
Getting it welded from the outside that way it won't affect the machining on the inside very much, certainly the 1st time I've seen anything like that from VW.
2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

vwrally

quick metal works a treat

my scirocco gearbox has been running like that for years

80 Vert

Yep that stuff does work well however box is apart now so welding is far better for proper fix.
2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

BB

Yes I was about to say you won't ever get Vert to do a bodge up if he can do the job properly. I'm sure in the middle of Africa he could also hammer a sliver of wood in that hole and send you off happy ;)
The end is nigh, but the end of what is the question?