Thread: TD5 Sump and Gearbox Alignment

While I was replacing the crankshaft rear main seal, I thought it would be a perfect opportunity to check the oil pump sprocket bolt. Taking the sump off with the gearbox, transfer case, cross member and exhaust all out of the way, made this a doddle. The oil pump bolt was firm...ish but certainly not 25Nm and no Loctite. So I did the job properly and then put the sump back on with a nice new OEM (Victor Reinz) gasket and the special STC50550 goo, all torqued up within the 20 minutes. Happy.

Then I noticed that the sump and gasket are both slightly overhanging the rear of the engine block, the sump by about 1mm (red arrows) and the gasket by up to 2mm (yellow arrow). There are no registration dowels between sump and engine block.
TD5 Sump Alignment.jpgTD5 Sump Alignment Driver's Side View.jpg
I’m guessing this isn’t good for gearbox alignment when I try to bolt that back on. I had considered loosening the sump bolts, bolting up the gearbox then re-torquing the sump bolts but I am concerned the goo sealing the gasket at the rear main seal will be dislodged (Sod’s Law).

Anyone come across this before and any better suggestions on how to fix would be appreciated.

Cheers

I have only ever changed the sump gasket with gearbox in place, it may pose a bit of issue as you say or it may just get squeezed up as the bell housing bolts back up.
Perhaps a trim of the exposed millimetre with a new blade in the stanly knife or a scalpel if you have one.

Good luck, Discofender