Hi all

My original gearbox was worn, making hissing noises and just didn’t feel right, I cured a judder a few monbths ago with an oil and filter change so I knew it was coming to the end of it’s life.

Huge problems with changing my L322 gearbox.

I bought a reconditioned gearbox on eBay (I know, I should not have, but I did!) fitted it to my car, started it up and all the oil from the gearbox came out of the bell housing.

I decided to get my original box reconditioned properly at a price of 1800 quid with 12 months warranty.

I have just finished fitting the box about an hour ago.

When I started the car, all the gearbox oil came through the bell housing.

The company who reconditioned the gearbox are not open till Monday so I can’t ring them to invoke the warranty.

A thought has occured to me, could something else cause this?

It wasn’t doing this before I started, yet I have had the same outcome with two separate gearboxes!!

Can anyone think of a reason why this is hapenning or shed any light?

Could I have done something wrong?

merlinpjl said:

Hi all

My original gearbox was worn, making hissing noises and just didn’t feel right, I cured a judder a few monbths ago with an oil and filter change so I knew it was coming to the end of it’s life.

Huge problems with changing my L322 gearbox.

I bought a reconditioned gearbox on eBay (I know, I should not have, but I did!) fitted it to my car, started it up and all the oil from the gearbox came out of the bell housing.

I decided to get my original box reconditioned properly at a price of 1800 quid with 12 months warranty.

I have just finished fitting the box about an hour ago.

When I started the car, all the gearbox oil came through the bell housing.

The company who reconditioned the gearbox are not open till Monday so I can’t ring them to invoke the warranty.

A thought has occured to me, could something else cause this?

It wasn’t doing this before I started, yet I have had the same outcome with two separate gearboxes!!

Can anyone think of a reason why this is hapenning or shed any light?

Could I have done something wrong?

Click to expand...

Torque convertor incorrectly positioned perhaps? You should replace the torque convertor when you do the box as the slipping clutch in the torque convertor is what fails and fecks the gearbox. You also need to flush or replace all the lines and the oil cooler to clear any dedris. Saint V8 will know more.

The torque converter was part of the recon, it has been replaced and was in position in the bell housing when it came back. There was a stop, made from cardboard in place to prevent it from moving. I kept the cardboard in place right up to offering up the gearbox to the flywheel and then removed before bolting the gearbox in place.

The only option IMO is to send the G'box back to them..

Oh and as Datatek says i would flush the oil cooler and lines out, or better still replace 'em

i wouldn't want all that old debris going through my new gearbox!

merlinpjl said:

The torque converter was part of the recon, it has been replaced and was in position in the bell housing when it came back. There was a stop, made from cardboard in place to prevent it from moving. I kept the cardboard in place right up to offering up the gearbox to the flywheel and then removed before bolting the gearbox in place.

Click to expand...

How

merlinpjl said:

The torque converter was part of the recon, it has been replaced and was in position in the bell housing when it came back. There was a stop, made from cardboard in place to prevent it from moving. I kept the cardboard in place right up to offering up the gearbox to the flywheel and then removed before bolting the gearbox in place.

Click to expand...

Maybe removed the cardboard too soon, or it just wasn't strong enough to keep the torque convertor in place.

Datatek, it is a possibility but it did feel OK and went in flush to the flywheel with no forcing. It seemed to go together as you would expect it to.
However, something is clearly wrong. I'm hoping that the reconditioning company will take the vehicle and have a look.

This is based on my experience with the ZF on the RRC & a quick look at pics of the L322 TCs where it uses ZF boxes & the input shaft side of the TC on those looks the same.

The ZF box torque converters must be fitted to the gearbox before mounting up to the engine & seated to the correct depth. Ashcroft list seating depths for the ZF on the Classic & P38 based on the gearbox number but I don't think they deal with the later boxes - although I stand to be corrected!
The depth is measured from a straightedge across the bellhousing mouth to the front of any of the lugs on the front of the TC.
The TC is free to slide & will happily slide forward & off the gearbox input shaft. I made a T shaped piece of steel to hold mine in place & the first one I made was too thin & bent allowing the TC to fall off so I doubt cardboard is up to it. Can be a absolute pig to refit.

The hollow shaft on the gearbox side of the TC has 2 slots. These engage with & drive the gearbox pump. The smooth part of the shaft is what the gearbox input seal seals against.
Common problem is not seating the TC correctly & whilst it will all bolt up it will damage the pump which will then need replacing.
I wonder if this is what's happened (or if the input seal has been damaged/displaced whilst fitting the TC) & this is the cause of your leaks.

For the ZF 5HP24 transmission, the relevant dimension from the bellhousing face to the four mounting pads is 25mm, when the torque converter is installed correctly.



To prevent damage to the input seal, caused by converter movement during shipping, my transmissions are all supplied with the correct ZF retention bracket fitted. This holds the torque converter rigidly in the correct position.



Phil

I guess that Phil has effectively confirmed that the torque conertor was not correctly in place and has fecked the seal.

Datatek said:

I guess that Phil has effectively confirmed that the torque conertor was not correctly in place and has fecked the seal.

Click to expand...

And possibly the pump as well.

Thanks Phil. That's a substantial piece of metal keeping it in place!

ETA Wonder if there's an issue under the warranty if they've not supplied it with the proper retaining device which would put the liability on them?

Ratae said:

And possibly the pump as well.

Thanks Phil. That's a substantial piece of metal keeping it in place!

ETA Wonder if there's an issue under the warranty if they've not supplied it with the proper retaining device which would put the liability on them?

Click to expand...

Certainly beats the hell out of a piece of cardboard