Crankshaft Bolt Experiences & Gearbox Issues

Hello everyone!
My 15 HP Eicher (Passat 35i, '96, 1Z original, approximately 260,000 km) had been giving me more and more starting problems in the mornings for about 4 weeks, struggling to start, white smoke clouds, blue smoke when idling, the whole shebang .
Initially, I suspected the fuel system, as I had already been convinced for some time that the 12.9 screw was the issue, but I couldn't find any real errors there. After the problem became more severe, I ordered a timing belt kit and a new sprocket from my parts dealer, and yesterday it went onto the operating table. And lo and behold: the screw came off even without much force, using a regular ratchet! Fortunately, the stub on the crankshaft wasn't too badly damaged, so thanks to a kind suggestion from ATU FFB, I was able to smooth it out again in 5 minutes.
I suspect that when I bought the car with 98,000 km, and the timing belt had been replaced shortly before at VW, they installed the 'new' screw. However, when I reached 180,000 km and was due for another replacement, I was unfortunately unaware of this engineering 'masterpiece' and (unfortunately) left the sprocket untouched. And now, just 10,000 km before the next scheduled belt change, this damage has occurred despite the changed screw. Therefore, the labor involved is actually quite low if everything goes well, and that silly little screw isn't that expensive either; just replace it along with the timing belt!
'When I had the opportunity to have my Eicher on stage, I noticed something on the transmission... One of the two oil seals on the driveshaft flanges has popped out a bit (which I've seen very often on VWs...). Now the question: Is it a major undertaking to replace these oil seals on the 5-speed transmission, requiring complete removal and disassembly, or is it relatively simple? If so, how? Or, considering the amount of work involved, is it more sensible to carefully push the oil seal back into place and just check the oil more frequently?'

Best regards,

Dominique.

Hi Dominique,

Since you wrote a potentially helpful response to my 1Z problem, I wanted to briefly help you with your issue... If it's the constant velocity (CV) joint boot on your car, which I think it might be, then loosen the CV joint on the wheel bearing side, pull the boot outwards, and try to bend the shaft downwards or to the side. After that, with some force and maybe a little wiggling, you can push the CV joint outwards and pull it out until it comes out of the differential. However, be aware that when you do this, all the gearbox oil will leak out. Then, repair the boot (meaning, apply a generous amount of grease to the inside), reinsert the CV joint, refill the oil, and say, 'It's done!'

Alternatively, you can make it easier for yourself by finding something blunt and a small hammer and tapping the boot back in until it fits. That also works.

Best regards.