Leaky Gearbox - Superformance S1 (Zetec w/ Ford Type 9)

[Driven]

Found this photo while googling -- which looks like the gearbox that's in our 7. At least, that 3 bolt flange that's under the input shaft is identical.

The ol' girl seems to be leaking oil from that flange or possibly the input shaft and dripping down.

 

I'm guessing the easiest way to address it is to pull the entire drivetrain out instead of just dropping the gearbox?

 

But, once I get it out, I'm not sure where to go for replacement parts stateside.

 

Any advice would be appreciated before I tackle this project in the next few months.

[11Budlite]

Driven - I rebuilt my T9 with a BGH close ratio gearset back in the 2005-2007 time frame. Besides the gearset, I picked up parts from https://www.taylor-race.com/, http://batford.net/, and http://www.quantumechanics.com/ that were the only US suppliers that I knew of at the time. I'm not sure if these companies are still dealing in the Sierra/Merkur T9 transmission parts, but they're worth checking into. If all else fails you can always get the parts from the UK from various suppliers.

 

That 3-bolt flange/stub shaft is the same as the one in my old car and denotes the heavy duty T9's that used a bigger front roller bearing for the laygear. I did have an oil leak from the front of mine when I first put it together and had to take it back apart to replace the input shaft seal. I think I used Permatex Right Stuff instead of a gasket between the box and the bellhousing the 2nd time around too. I'm pretty sure I still have some detail photos at home that I can post later today of some things to look for. When it was back together, it was one of the nicest shifting gearboxes I've ever used with some great ratios for a seven.

[oilteq]

I used Quantum Mechanics for parts on one Birkin transmission, and for the whole transmission on another Birkin. I wish his parts and shop were cleaner, but overall good experiences.

[11Budlite]

I've attached a couple photos. The first one shows the different input seal designs that I used when I had my gearbox apart. The seal on the right is the original one that leaked and the seal on the left is the replacement that didn't leak. The one on the right was a single-lip seal while the one on the left was a double-lip seal with the spiral ribs on it. Funny thing was that I got both seals from the same supplier, but I can't recall if it was TRE or BAT. The second photo I found on the internet shows one of the problem areas for leaks. When I first assembled the gearbox to the bellhousing, I used a paper gasket with blue hylomar on both sides of it. The 3-bolt flange/stub shaft is a tight fit in the case and probably wouldn't leak, but I think I used a small layer of hylomar there too. My leak was coming from the input shaft seal, but others had leaks from around the shift rod so I decided to use Permatex Right Stuff in place of the thin gasket. The two mating surfaces have to be really clean so I use either alcohol or Brakleen with a clean rag and keep wiping it down until no grime/residue shows on the rag. After that I had no more issues.

 

"I used Quantum Mechanics for parts on one Birkin transmission, and for the whole transmission on another Birkin. I wish his parts and shop were cleaner, but overall good experiences."

 

You should have seen John's shop when he worked out of his garage. It looked like a stack of LBC transmissions, overdrives, and rear ends had been piled to the ceiling and there had been an explosion. There was literally parts everywhere! To his credit he knew right where everything was!

 

http://www.usa7s.net/vb/attachment.php?attachmentid=15911&stc=1http://www.usa7s.net/vb/attachment.php?attachmentid=15912&stc=1

[papak]

I found that the selector shaft was the source of the leak on my T9. Meticulously clean the surfaces and carefully apply either Hylomar or rev. Bone dry ever since.

[Driven]

I was hoping to be able to drop the gearbox without removing the engine -- anyone know if that's possible? Not sure if the firewall prevents access to the bellhousing bolts... or enough to clear the input shaft.

 

Thanks for the photos and advice so far, definitely helpful

[11Budlite]

I was hoping to be able to drop the gearbox without removing the engine -- anyone know if that's possible? Not sure if the firewall prevents access to the bellhousing bolts... or enough to clear the input shaft.

 

Thanks for the photos and advice so far, definitely helpful

 

I have no experience with the S1 so I don't know if that's possible, but maybe someone else has done it. According to the build manual, the engine and transmission are installed as a unit. Pretty good manual here: https://www.secondstrike.com/Technical/S1_Installation_and_Service_Manual.pdf

[S1Steve]

Sorry I’m late.. installed my engine per the manual and you’ll have no problem.Did mine once 16 years and 24000miles ago...