Replaced my TD4's (manual) gearbox oil with some MTF94 yesterday. As instructed, I first opened the filler/level plug. Surprisingly, about 1.2 litres of oil gushed out of the filler hole. I then opened the drain plug, and another 0.5 litres came out the drain hole. Why did so much oil come out the filler hole?

The engine was warm at the time. I had driven 60 miles, then stopped for about 20 minutes, then drove another 2 miles to re-warm the engine, then took about 20 minutes until the filler plug was open.

Also, the front wheels were lifted about 25cm at the time.

Any ideas?

... and I'm now nervous to re-check the level, in case it comes pouring out again. (By the way, I did drop the front down to level before re-filling. It took about 1.6 litres to re-fill.)

seraphin said:

... and I'm now nervous to re-check the level, in case it comes pouring out again. (By the way, I did drop the front down to level before re-filling. It took about 1.6 litres to re-fill.)

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The TD4 gearbox capacity from dry is 1.6 litres according to the manual. Assuming you managed to get all of the oil that was in there originally drained, I'd say you're there or there about with the amount you've put in. Maybe slightly over.