Grease in the space between the engine and gearbox WTF???

[bartolomeus]

We have taken the gearbox down from 2.2t
We found massive amounts of grease on the engine.
We can't figure out from where the grease is???
This is a serious problems because the sensors were full of grease and maybe the engine stopped working properly?

The driveshafts rubber sealers were OK. The crank ring was OK. From where the f. the grease came???

[UrS4boy]

Four reasons for oil/grease in bell housing

We have taken the gearbox down from 2.2t
We found massive amounts of grease on the engine. We can't figure out from where the grease is??? This is a serious problems because the sensors were full of grease and maybe the engine stopped working properly?

I think there are four choices:

1. Transmission fluid leaking past the input shaft seal
2. Engine oil passing through the rear crank seal
3. Clutch fluid (actually brake fluid) leaking past a failed slave cylinder.
4. Bolt came loose in clutch area and resulted in a machined hole in the transmission case

The first 3 are dealt with in this post (with PNs):

http://forums.quattroworld.com/s4s6/msgs/291460.phtml

These are examples of the 4th "option":

Example 1:



Example 2:

[rxl]

no 3.

[bartolomeus]

It's grease that we have there, not oil, not dirty oil, not thicked dirty oil. It's grease.



We already checked 1-4 and it's not our case.
Could this grease come from the dual mass flywheel?

[UrS4boy]

Dual Mass Flywheel info

Could this grease come from the dual mass flywheel?

First time I've heard of this as a DMFW failure but, yes, it is possible.

Here is what LUK says about their DMF:

"A standard Dual Mass Flywheel consists of the primary flywheel (1) and the secondary flywheel (6). The two decoupled masses are connected via a spring/ damper system and supported by a deep groove ball bearing or plain bearing (2) so they can rotate against each other. The primary mass with starter ring gear is driven by the engine and tightly bolted to the crankshaft. It encloses, together with the primary cover (5) a cavity which forms the arc spring channel. At the heart of the spring/ damper system are the arc springs (3). They sit in guides in the arc spring channels and cost effectivley fulfil the requirements of an "ideal" torsion damper. The guides ensure correct guidance of the springs during operation and the grease around the springs reduces wear between the guides, channels and the springs. Torque is transferred via the flange (4). The flange is bolted to the secondary flywheel with its wings sitting between the arc springs. The secondary flywheel helps to increase the mass moment of inertia on the gearbox side. Vents ensure better heat dissipation. As the DMF has an integral spring/damper system, a rigid clutch disc without torsion damper is normally used."

DMFW info: http://forums.quattroworld.com/s4s6/msgs/24536.phtml

[domas]

Maybe somebody greased throwout bearing?

[UrS4boy]

Reason why fluid(s) might their way into the 01E transmission bell housing

I think there are four choices:

1. Transmission fluid leaking past the input shaft seal
2. Engine oil passing through the rear crank seal
3. Clutch fluid (actually brake fluid) leaking past a failed slave cylinder.
4. Bolt came loose in clutch area and resulted in a machined hole in the transmission case

The first 3 are dealt with in this post (with PNs):

http://forums.quattroworld.com/s4s6/msgs/291460.phtml

That link has now been updated to include the 5th possibility

1. Transmission fluid leaking past the input shaft seal
2. Engine oil passing through the rear crank seal
3. Clutch fluid (actually brake fluid) leaking past a failed slave cylinder.
4. Loose bolt machining a hole through the bell housing
5. Dual Mass Flywheel Failure, letting its grease out.

Reason why fluid(s) might their way into the 01E transmission bell housing:

http://forums.quattroworld.com/s4s6/msgs/291460.phtml

[orignalS60]

Sometimes it will appear as grease but leaks of any type of fluid over time
build up and get thick and greasy. I see it on peoples cars day in and day out.
Sometimes even from a prior leak that was fixed but nobody cleaned up the mess.