Engine: D5: Still leaking after new core plug and oil seal

[S60man]

After discovering a sudden and serious oil leak coming from the weep hole of the gearbox bell housing of my 2003 D5 and, after reading everything I could find on the subject on this forum, I decided it must be the core plug above the crankshaft that had come loose.
I bit the bullet and pulled the gearbox clutch and flywheel to find the core plug turned in the housing. I replaced the core plug with a new metal one from Volvo and to be on the safe side replaced the crankshaft oil seal. The oil seal Volvo supplied was of a different construction to the old one but it fitted fine.
After putting it all back together I thought job well done only to discover a week later engine oil was still leaking badly from the gearbox weep hole.
I have read on the forum members suffering the same problem when a main dealer carried out the work and returning the car to volvo to put right but I've never found out what they did.
Could it be a pressure build up in the crank case pushing oil past the seal due to a blocked oil separator? Any ideas would be most welcome.

[DieselDoNicely]

Thats a bugger, its another strip down if its not over pressure.

DDN

[reesky]

Hmm. When my core plug went the slave cylinder was also leaking. Did you change the slave cylinder too?

Presume you're sure it's engine oil and not brake fluid?

Ta

[S60man]

It is definitely engine oil and I changed the release bearing clutch and flywheel a year ago. If only I knew about the core plug weakness then I could have done that at the same time in 5 minutes flat.

I am pretty sure the core plug is ok now but I must have messed up the crankshaft oil seal. It went in fine but I didn't have the special insertion tool 9997174.
Anyone know where i can borrow/buy one from as I don't want to mess it up again?

[coughlanc]

http://www.v-garage.ca/volvo_main_re...tion_tool.html

[D5meister]

could be box oil??

If it is the crank seal, the spring may have rolled off the back of seal lip, they do that very easily. Then, the seal can pucker or lacks grab and can weep.

they can get nicked on a scrap of rust as they slide onto the crank...

The clutch should survive as the oil doesnt get thru the flywheel.


If u try a marigold glove over the oil filler - tether with some strong bands around fill neck.

It will inflate but shouldnt keep going or blow off.

You could mod a scrap filler cap with a 1bar clock from the bay. I started this but didnt need.

[Clan]

Originally Posted by S60man

After discovering a sudden and serious oil leak coming from the weep hole of the gearbox bell housing of my 2003 D5 and, after reading everything I could find on the subject on this forum, I decided it must be the core plug above the crankshaft that had come loose.
I bit the bullet and pulled the gearbox clutch and flywheel to find the core plug turned in the housing. I replaced the core plug with a new metal one from Volvo and to be on the safe side replaced the crankshaft oil seal. The oil seal Volvo supplied was of a different construction to the old one but it fitted fine.
After putting it all back together I thought job well done only to discover a week later engine oil was still leaking badly from the gearbox weep hole.
I have read on the forum members suffering the same problem when a main dealer carried out the work and returning the car to volvo to put right but I've never found out what they did.
Could it be a pressure build up in the crank case pushing oil past the seal due to a blocked oil separator? Any ideas would be most welcome.

Not much help to you now i know , But i have said on here many times , if your rear crank seal is dry always leave it well alone whatever the mileage ...

You really must use the special tool to fit the new type seal it holds the seal away from the Crankshaft whilst you fit the seal , the lip is probably turned over on itself .

[ksmi]

Originally Posted by Clan

Not much help to you now i know , But i have said on here many times , if your rear crank seal is dry always leave it well alone whatever the mileage ...

You really must use the special tool to fit the new type seal it holds the seal away from the Crankshaft whilst you fit the seal , the lip is probably turned over on itself .

Afternoon Clan,Can the fitting tool be purchased at the parts counter? How many Shekels? Not that I need one, but listening to the tales of woe, it would be worth its weight in,,,,, if doing the rear crank seal,otherwise a bit like Russian roulette. BTW thank you for all the info. you give, often think ah,Clan will probably know! and lo and behold....

Regards.

Keith.

[cheshired5]

I would recommend asking FRF for a price for the correct tool as they have been one of the few dealers who will supply the Volvo workshop tools to retail customers.

I've had 3 workshop tools from them now which usually take a week to arrive as they're not stock items and arrive direct from Sweden.
All of them were overpriced for what they are but the important thing is that they are correct, work exactly as required and can always be sold on or hired out to mitigate costs.

[Clan]

Originally Posted by ksmi

Afternoon Clan,Can the fitting tool be purchased at the parts counter? How many Shekels? Not that I need one, but listening to the tales of woe, it would be worth its weight in,,,,, if doing the rear crank seal,otherwise a bit like Russian roulette. BTW thank you for all the info. you give, often think ah,Clan will probably know! and lo and behold....

Regards.

Keith.

Hello Keith ,
Thanks for your comments 😊 Yes the Volvo special tool for the rear crankshaft seal 999 7174 is available from any volvo parts counter . don't take no for an answer , Its them being lazy if they give any excuse .

I would guess the price is £50 - £70 but yes worth it's weight in gold .
Its very rare a volvo rear crankshaft ever leaks , it is normal for them to be bone dry .

Keep Safe , Clan