Eek, debris and all.I've been keeping a low profile as I've been working on doing the gearbox swap on my driveway....(about half way through) but I thought I would share a picture of the drain plug when draining the oil from the gearbox:
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Yeah that gearbox is goosed...and I don't think an oil change will save it... At least 4 large curved very sharp shards of shiny steel - on the order of 8mm long by 3mm in diameter each. And I haven't even checked the level plug - which also has a magnet in these gearboxes...
Anyone game to take a guess at where the shards come from? Given their curvature and size I'm sticking with the chipped gear theory...
I drained the oil into a measuring jug and got exactly 1.4 litres so it wasn't short on oil. The oil is completely black and opaque so I don't know how much other metallic residue might be in it.
Of course Murphy had to throw a spanner in the works - in the last 2 days while the Leaf has been up on stands the 12v battery has gone completely dead - it was right down to 4v which was too low for my intelligent charger to believe it is a car battery and not a motorcycle battery.
I had to use my hobby RC charger to start the charging and get the voltage high enough for the other charger to believe it was a car battery. Chances are discharging so low has done permanent damage (Lead Acid batteries don't like full discharges) so I may be up for a new 12v battery at the end of this which is a shame as I've had no problems at all with the 12v battery in this Leaf.
The car had already sat for 3 weeks without being used with no sign of 12v battery discharge, (and I occasionally used the timed climate control which would give the 12v battery a 15 minute charge session) so I think what has caused it is following the procedure to disable the parking brake.
Normally you can't turn off the car without the parking brake locking automatically, for removal of the gearbox you don't really want the parking brake engaged - the Nissan procedure to avoid this is to put the car in neutral then pull a certain fuse under the bonnet before turning the car off - this cuts power to the parking brake actuator.
However I had noticed that while on the car was constantly complaining about "put the car into park" after I did this and I'm guessing that the ECU in charge of operating the parking brake did not go to sleep when the car was turned off as it was still monitoring the parking brake status. Hence the battery went flat. Argh!! So if you disable the parking brake using the Nissan recommended fuse pulling method make sure you disconnect the 12v battery soon after.
Anyway, back to work...