S1 gearbox input and output shaft leaks

[lancia7550]

While having the subframe separated from my car for engine work I am also carrying out various other jobs while access is easy.

I have noticed my gearbox input shaft is leaking a bit into the belhousing and the side shafts are also leaking.

I have bought a gearbox gasket kit including oil seals to tackle this job.

When I removed the inner side shaft it appeared if the oil came from inside the inner CV. Is this possible/ how does it happen? I have seen some forum posts discussing sealing two bolts that hold the output shaft, but on my car there is a big nut that holds the output shaft (needing a special Lancia tool) I can not see how it can leak from here, unless it leaks through the spline?

On the input shaft, it appears in the parts book diagram that there are two seals. The gasket kit only appears to have one seal though. Am I interpreting the diagram correctly and is this a seal I can easily buy?

Any other tips and tricks to do this job right?, E.g how do you lock the output shaft to remove the nut? (I should be able to borrow the tool).

[racing]

This O-Ring solution is only possible for 2.Serie 5speed gearbox. Depent on the different side shafts design.

S1 has a groove nut for fastening. Maybe something like this is also possible for S1. You have to take a look
whether this is possible or not.

regards Andreas

[racing]

wrong post should be in the german forum.

[Huib]

The flanges and their fastening are totally different between S1 and S2. The S2 has the problem with the breaking of the small M6 bolts. The system of the S1 is much better. It hardly gives problems but sometimes it does. The splines don't stop the oil but the nut does. Sometimes it does not.

It may leak under the nut. Just check very carefully that flange and bottom of nut are flat and without damage. Are the three lock bits in the groove inside the flange ok?

And it can leak along the thread between nut and half shaft. If thread is ok torquing the nut correctly is enough.

Alternatively one can cut a red copper washer and put under the nut. And use sealant on the thread.

Put something through one of the M8 holes in the flange and lock it against one of the M8 studs to keep the flange in place when torquing the nut.

On the input shaft there is the main seal preventing oil from leaking into the clutch housing. Behind the seal is a oil bath to keep the seal lubricated. The part that holds the seal and the bush with the needle bearing has a hole at the top to collect oil and it has a hole at 45 degrees from the bottom. So there should be oil at the bottom for lubrication of the seal. In situations where the oil leaks out of that small chamber through the needle bearing faster than the oil flows in at the top you want and extra seal for preventing that. That is the small seal. It wasn't there on the earlier Fulvia's. I always though it was added on the S2 gearboxes. Apparently it was already there on your S1 gearbox. It is available in the seals shop. Or reuse it. If it has damage make sure the part that is at the bottom is ok.

The bushes for the yoke at the top leak too. Quite a bit. They should be replaced.
And, very important, take flywheel + clutch disc + pressure plate to a specialist. Adjusting it correctly and put the right thickness of friction material on the disc is vital.

Use Millers CRX75W90 Synth or equivalent oil.

[lancia7550]

Thank you so much for your reply Huib and Andreas.

[lancia7550]

Any tips on removing the front seal in the belhousing? I have all but destroyed it by trying to use a sharp pic to pull it out, but I can't get it out.

[Huib]

I use what is called a bearing puller