Oil leak

[edstacey]

Hi! I am English living in Spain and I found your site most interesting and knowledgable and so decided to join. I have a 1994 300series TDI auto, I have engine oil coming from the belhousing drain plug hole. do you think it could be a rear main oil seal? If so would you recommend to take the engine out & leave the gearbox in or gearbox out leaving the engine in to replace the seal. Many thanks Ed Stacey

[Disco Mike]

We don't have many diesels in the US, but I believe it i safe to say your rear main seal is shot. As to the best way to remove it, I can't say, but I would suggest you plan on changing your clutch while you are in there, it will probably have an oil soaked disc. Also check the front seal on the transmission, I would change it out just cause you are in there, might want to talk to someone who is familiar with them.
Wish I couls be more help.
Mike

[wade]

The steps below are for a 300 TDI..It is from the RAVE cd which I understand is free, but don't know the website. The CD has drawings and photos also. I purchased mine for a few bucks on ebay. All the "See Manual Gearbox Repair" refers to another section on the CD. Hope it helps you.

CRANKSHAFT REAR OIL SEAL
Service repair no - 12.21.20
Remove
NOTE: The crankshaft rear oil seal is
retained in its own housing, if the seal
requires replacing the housing and seal
assembly (1) must be renewed complete with the
housing seal (3). Housing and seal assemblies are
supplied with their own former/seal guide (2)
already fitted. This former must not be removed
before fitting the assembly to the engine. If a seal
and housing assembly is received without a
former/guide fitted it must be returned to the
supplier. Used formers/guides must be discarded
immediately after use, under no circumstances
should they be reused on other assemblies.
1. Disconnect battery negative lead.
2. Remove gearbox. See MANUAL GEARBOX,
Repair, R380 Manual Gearbox
3. Remove clutch. See CLUTCH, Repair, Clutch
Assembly
4. Remove flywheel. See Flywheel
5. Remove five bolts and withdraw seal housing
and seal assembly complete with gasket.
Refit
6. Insert slave studs to seal housing mounting face.
7. Position new seal housing gasket over slave
studs and crankshaft flange onto cylinder block.
8. Ensure housing seal is correctly seated in its
groove in new housing and seal assembly.
9. Fit new assembly, with former/guide in-situ, over
crankshaft flange, this action will eject
former/guide.
10. Secure assembly to cylinder block with five bolts
tightened to correct torque, removing slave studs
individually and inserting bolts.
11. Refit flywheel. See Flywheel
12. Refit clutch. See CLUTCH, Repair, Clutch
Assembly
13. Refit gearbox. See MANUAL GEARBOX,
Repair, R380 Manual Gearbox
14. Reconnect battery negative lead.
8. Ensure housing seal is correctly seated in its
groove in new housing and seal assembly.
9. Fit new assembly, with former/guide in-situ, over
crankshaft flange, this action will eject
former/guide.
10. Secure assembly to cylinder block with five bolts
tightened to correct torque, removing slave studs
individually and inserting bolts.
11. Refit flywheel. See Flywheel
12. Refit clutch. See CLUTCH, Repair, Clutch
Assembly
13. Refit gearbox. See MANUAL GEARBOX,
Repair, R380 Manual Gearbox
14. Reconnect battery negative lead.

[edstacey]

Originally Posted by Disco Mike

We don't have many diesels in the US, but I believe it i safe to say your rear main seal is shot. As to the best way to remove it, I can't say, but I would suggest you plan on changing your clutch while you are in there, it will probably have an oil soaked disc. Also check the front seal on the transmission, I would change it out just cause you are in there, might want to talk to someone who is familiar with them.
Wish I couls be more help.
Mike

THANKS MIKE FOR YOUR HELP

[edstacey]

THANKS WADE THIS IS JUST WHAT I NEEDED

Originally Posted by wade

The steps below are for a 300 TDI..It is from the RAVE cd which I understand is free, but don't know the website. The CD has drawings and photos also. I purchased mine for a few bucks on ebay. All the "See Manual Gearbox Repair" refers to another section on the CD. Hope it helps you.

CRANKSHAFT REAR OIL SEAL
Service repair no - 12.21.20
Remove
NOTE: The crankshaft rear oil seal is
retained in its own housing, if the seal
requires replacing the housing and seal
assembly (1) must be renewed complete with the
housing seal (3). Housing and seal assemblies are
supplied with their own former/seal guide (2)
already fitted. This former must not be removed
before fitting the assembly to the engine. If a seal
and housing assembly is received without a
former/guide fitted it must be returned to the
supplier. Used formers/guides must be discarded
immediately after use, under no circumstances
should they be reused on other assemblies.
1. Disconnect battery negative lead.
2. Remove gearbox. See MANUAL GEARBOX,
Repair, R380 Manual Gearbox
3. Remove clutch. See CLUTCH, Repair, Clutch
Assembly
4. Remove flywheel. See Flywheel
5. Remove five bolts and withdraw seal housing
and seal assembly complete with gasket.
Refit
6. Insert slave studs to seal housing mounting face.
7. Position new seal housing gasket over slave
studs and crankshaft flange onto cylinder block.
8. Ensure housing seal is correctly seated in its
groove in new housing and seal assembly.
9. Fit new assembly, with former/guide in-situ, over
crankshaft flange, this action will eject
former/guide.
10. Secure assembly to cylinder block with five bolts
tightened to correct torque, removing slave studs
individually and inserting bolts.
11. Refit flywheel. See Flywheel
12. Refit clutch. See CLUTCH, Repair, Clutch
Assembly
13. Refit gearbox. See MANUAL GEARBOX,
Repair, R380 Manual Gearbox
14. Reconnect battery negative lead.
8. Ensure housing seal is correctly seated in its
groove in new housing and seal assembly.
9. Fit new assembly, with former/guide in-situ, over
crankshaft flange, this action will eject
former/guide.
10. Secure assembly to cylinder block with five bolts
tightened to correct torque, removing slave studs
individually and inserting bolts.
11. Refit flywheel. See Flywheel
12. Refit clutch. See CLUTCH, Repair, Clutch
Assembly
13. Refit gearbox. See MANUAL GEARBOX,
Repair, R380 Manual Gearbox
14. Reconnect battery negative lead.