I've traced the source of a clutch fluid leak on my car to the clutch damper, which is a smallish flat square shaped thingy located above the clutch slave cylinder.

My mechanic originally identified the leak when he was going over the car to fix all the **** that the gearbox shop ****ed up when they rebuilt / refitted my box, he told me he had tightened the 4 bolts on the damper and thought that had fixed the problem - but it obviously didn't.

I've just checked the tension of the 4 bolts again - and they are all pretty tight. I've consulted the workshop manual - which states that these bolts only need to be tensioned to 18nm (not very tight at all).

My question is - is there supposed to be a rubber gasket or seal underneath the top plate of the damper, because if it's leaking - and the bolts aren't supposed to be done up very tight, then the only thing I can think of is that it's missing a gasket. Can't see anything in the workshop manual regarding a gasket.

So does anyone have any ideas?? I'm kinda desperate - I've completely drained the clutch fluid twice after only 150km's or so of driving.

Okay - think I've found out why it's leaking....... but it's got me completely stumped how this happened....

I got curious and removed the top cover of the damper, first pic shows the underside of the cover, and the small steel ring that was sitting under the cover.

http://i99.photobucket.com/albums/l292/black_beard_2006/P1010035.jpg

Second pic shows the damper cover plate side on...... I'm pretty sure even in the photo you can see that it is warped - which explains why I witnessed clutch fluid leaking out from the center of the edge (between the bolts) when the clutch pedal was being pressed.

http://i99.photobucket.com/albums/l292/black_beard_2006/P1010038.jpg

Now I definetly wasn't loosing clutch fluid before the gearbox went in for a rebuild after the latest diff failure - so I can only assume something happened when the clowns at the gearbox shop were stuffing around with it. I know they had "issues" with the clutch when they refitted the box, but they weren't too forthcoming with information regarding these "issues". I do know that they claim that they replaced the clutch fork twice before they "got it working", and they also took to my bell housing with an angle grinder, and didn't refit the clutch fork boot.

I'm wondering if somehow in their ****ing around with the clutch system, they managed to build up so much pressure in the hydraulic system that it warped the damper plate. I can just picture those ****ing meatheads stomping the **** out the clutch trying to get it to work.

how is the reputation of these guys?

seems a bit odd that they would **** a gearbox up that bad?!

you can try and reverse the plate and use the other side of it when bolting it back on

flatten it with a light tapping with a hammer

next you might try making a gasket

EDIT

how is the reputation of these guys?

seems a bit odd that they would **** a gearbox up that bad?!

Earlier this evening, out of curiosity I googled "gearbox shop" and within the first few pages of hits, I came across at least 3 forum threads with posts from people who had similar experiences to mine......

Here's a ripper (4th post) (http://www.fordmods.com/forums/post738994.html?highlight=)

Here's another one. (http://redlineau.com/forum/viewtopic.php?t=9892&view=previous&sid=b30dcb01993670dfd4b0684c1de0d488)

If I'd read those before hand, I never would have taken the car there. Main reason I took it there was because it was close to where the car broke down (minimise towing costs), and they have another workshop in Slacks Creek - who actually rebuilt my gearbox the first time, and by all accounts they are really good. I made the mistake of assuming that all "The Gearbox Shop's" would be just as good.

you can try and reverse the plate and use the other side of it when bolting it back on

flatten it with a light tapping with a hammer

next you might try making a gasket

Hey mate - thanks for the input. I need the car tomorrow, so I was going to try reversing the plate. If that still leaks, I'll take the plate off and try to find an engineering place that can make me a new one next week..... it's just a piece of ~4mm thick steel, approx 50mm square with 4 bolt holes in it. Should be a hell of a lot easier getting a new one cut than finding one at a wreckers.

gabba gearboxes had a good rep with the inline gearboxes as exchange

now must have lost the plot with the front wheel drive ones
but this example looks like they dont take care in how the fit the boxes back in

I might be mistaken - but I think "Gabba Gearboxes" are someone else. This mob I delt with are "The Gearbox and Diff Shop", they are in Nile St.


***EDIT FOR ANYONE READING THIS WHO IS INTERESTED***
Bolting the damper cover back on upside down has stopped the leak of clutch fluid.

edited the gearbox shop part

keep within the low torque spec
the plate is only ment to press against that ring to make the seal

if the ring has been flattened or squashed try turning it over

if it leaks you may need a new ring