Pipe connection to new CSC leaking 2004 Tourneo Connect

[megaross]

Had to drop the gearbox after the high tensile bolt I used to repair the shift turret snapped. Changed the clutch whilst it was out and with it fitted a new CSC

The CSC in question was a slightly different design but I didn't think anything of it since it's aftermarket. Figured it's ford, it's a common gearbox, probably just what they make now.

Only thing is the connection is leaking to it, there was a kind of adapter with an o ring on the end of the pipe so I tried removing that and running the end piece straight up (with the conical seal). However that is still leaking slightly.

Bit bemused, I really don't want to drop the box again as that was a horrendous job on axle stands in the piss pouring rain.

Ordered a new CSC pipe hoping that'll solve my issues. Does anyone have any thoughts as to what the issue might be or ideas to resolve this?

Wondering if maybe theres an early and a late clutch pipe or something? I know it's the same MTX75 box used throughout.

Pics - old csc, connector thing, new csc

[metalworker0]

Seems lot of people here had the same problem . and did not get an answer ..but one person reckons he left the seal inside or something :

viewtopic.php?f=54&t=175266&p=1491169&hilit=clutch+leaking#p1491169

That's all i can do to help ..having not been near my vans clutch, so i don't know what the set up is really, not familiar with it.

There are a few posts here in the other forums M6 / 7 ..similar thing to yours , seams a regular thing , with answers and solutions.

Use search words: clutch leaking.

all the best.mark

[megaross]

Thanks Mark,

I did have a search, unfortunately the threads I can find seem to be about leaks inside the bell housing or leaving a seal behind.

I had a really good look for anything leftover and I did get a seal out of the adapter pipe thing which helped but didn't cure.

Had my mate over helping (trained mechanic) and in between him complaining about the lack of a ramp he was just as confused as I was about it leaking when we were bleeding it.

Only thing I can think is there's an early and a late model CSC and I need to cobble together a hose with the right connector and hope the operation of it is the same.

Or I could cocoon the current one in PTFE and pray it never fails.

Ordered a new hose anyway, ECP sell one and it's the same for my reg and a later reg I put in. I'll have to report back when I pick it up this morning

[megaross]

So I've cocooned the new one in PTFE and it's sealing.

After trying two pipes (one was the same as the adapter, one the same as the black part) I just decided to try it.

Is it right? No. Is it good enough for a £1500 workhorse? Maybe, time will tell.

Only thing now is it's making a clunking and almost rubbery squeaking noise under load, seemingly coming from the passenger side. Not sure what to make of it.

Wondering if I overtightened the hub nut, my torque wrench maxes at 250nm so I added a good gronk with the massive breaker bar.

Also suspicious of the CV joints, one did come apart when I pulled that axle. I put it back together but maybe something is now not right beneath the boot.

[metalworker0]

I've sort of worked out if its 20 years old and never had an inner cv boot in its life, the thing will be dry, or about to run out of grease.

all the best.mark

[g-man]

Is it making a noise when reversing on full lock?

[megaross]

When the wheel rotates it's pushing the box back, happens at the 180 mark on the wheel front of back. Catches and pushes against the box, can literally see the box move back from the wheel well.

I'm guessing the CV joint is weirdly seated and it's mashing against the box or something has fallen apart. That passenger side one is a nightmare - the circlip is horrific to get out and just as hard to get in, had to give it a good tap with a lump hammer to get it to go in all the way.

[metalworker0]

They reckon you should have the open ends of the circlip uppermost, so they sit down in the groove and don't catch .

all the best.mark

[megaross]

Interesting, I just stuck a new driveshaft in and clouted it with a lump hammer again. Vans sorted, touch wood (other than the speed sensor, guessing it got mashed on install)

Was it good for the CV joint? Probably not.

Is it a terrible design? Absolutely.

Thanks for your help gents

[metalworker0]

You just got to remind yourself when hitting the end of the drive shaft, that the tripod inside of it, will be up against the back of the cup, so could damage the tripod in such a way that it could lead to early drive shaft failure.

so if you have to hit it hard, make sure its up against the back/ bottom of cup ,,, and not shocking against it...NO GAP ...you'll be holding the drive shaft and pushing in.

mine went in quite easy .....was it due to me recently (a couple of months back: ill find the video) learning about the circlip position ...i don't know ..but sure it helped.


all the best.mark

[metalworker0]

drive shaft installation tip

https://www.youtube.com/watch?v=lYHxT8aItpY

his follow up
https://www.youtube.com/watch?v=Qo4aeTEFGZs

all the best.mark