Ford Focus Mk1 drive shaft/differential housing leak

Ush1

Hi,

Having a problem with a drive shaft leak on a '04 Focus. It looks like when someone tried to remove the drive shaft they hacked at it and have nicked the metal. I initially thought it was the rubber drive shaft seals but they have been changed and it's still leaking. I got underneath and took a picture to show the gash from where the drive shaft enters the housing:
DSC00109.jpg

Now my question is, what would be the best way to seal this up. I'm thinking some sort of poxy resin as it would be too expensive and alot of trouble to replace that part of the housing altogether?

What sort of resin would be best do you reckon? I spose I would just smear it, let it harden then sand it down. Would have to remove the drive shaft to get at it properly anyway.

Slidey

It looks pretty butchered alright.

Epoxy resin is not going to help you there. The reason it is leaking is because it is not sealing. The seal may well have been damaged putting it in.

The best bet would be to remove the shaft and try and replace the seal. Before you do this it would be wise to check a few things.

Is the box over full?
Is there a breather on the box and is it blocked?
Is the oil of the right viscosity?
Is there and up and down play in the drive? If the bearings in the diff in the box are showing signs of wear this movement will in turn wreck the seals and cause leakage

Ush1

Slidey wrote: »

It looks pretty butchered alright.

Epoxy resin is not going to help you there. The reason it is leaking is because it is not sealing. The seal may well have been damaged putting it in.

The best bet would be to remove the shaft and try and replace the seal. Before you do this it would be wise to check a few things.

Is the box over full?
Is there a breather on the box and is it blocked?
Is the oil of the right viscosity?
Is there and up and down play in the drive? If the bearings in the diff in the box are showing signs of wear this movement will in turn wreck the seals and cause leakage

Well I only just got the seals replaced and the gear box oil changed so I think the seals should be okay and the gear box oil is the correct 75w90. I spose I'll need to remove the driveshaft to see fully but you reckon it's not leaking from the gash in the metal? I'll check the gearbox oil level aswell but I think it's okay for the moment.

kasper

i think if it was the seal the oil would be more sprayed around the area ,good photo but hard to see clean oil . it could be a crack on the casing if someone used a lever to extract the shaft

Ush1

Went to check the gearbox oil level today. When I opened the filler plug the oil started coming out, so I put the plug back in. May have been as it was still somewhat warm and expanded or could be overfilled. Oil is certainly clean and new anyway.

Plug

I see the part of the gearbox broke off, did you get a new clutch, I suppose they were taking out the drivshafts with a big pry bar and that happened.

I've seen a good few focus gearboxs with that broke off and hasen't caused a gearbox leak. The only thing that leaks around there is the seal, it would be really pissing out if the gearbox case was properly broke i.e. a hole in the gear box, that peice gone off he box would not cause a leak.

It looks like that seal is damaged. They probably made sh!t of the seal when they were putting back in the driveshaft.

Ush1

Plug wrote: »

I see the part of the gearbox broke off, did you get a new clutch, I suppose they were taking out the drivshafts with a big pry bar and that happened.

I've seen a good few focus gearboxs with that broke off and hasen't caused a gearbox leak. The only thing that leaks around there is the seal, it would be really pissing out if the gearbox case was properly broke i.e. a hole in the gear box, that peice gone off he box would not cause a leak.

It looks like that seal is damaged. They probably made sh!t of the seal when they were putting back in the driveshaft.

Yes he put in a new clutch!

Yeah, I was thinking that the seal would close that all in not matter what nicks or gashes are below it. The mechanic said he pushed the seal abit further in to try and stop it. I'm gonna get it up on axle stands, clean the entire underneath, drive for a while and check the underneath again.

Ush1

Bit of resolution on this. Found after proper cleaning that it was actually coming from the driver side drive shaft, not that side at all! It does seem indeed to be the seal so the mechanic is coming out to check and change the seal if nessacery.

Thanks for all the help.

Slidey

Thanks for the update

galwaydude18

Can I ask where do you check the gear box oil level in a 1.2 punto? Sorry for hijacking the thread!

Hal1

galwaydude18 wrote: »

Can I ask where do you check the gear box oil level in a 1.2 punto? Sorry for hijacking the thread!

Try here.