Just to give a full update on this problem, It ended up being the gearbox differential bearing or crownwheel. I had discovered there was less than a cup full of oil left in the gearbox.
I topped up the gearbox and it's done at least another 1000 miles of short journeys.
I purchased a secondhand gearbox off Ebay (I know...) and have just fitted it.
All was going well until I noticed when putting the nearside driveshaft back in complete with new oilseal that it didn't seem to go in as far as in the old gearbox.
I had made sure I pushed it fully in until I heard the ding as it met the stop. Looking at the driveshaft oilseal there is still about 5mm of shiny shaft showing.
I got the car fixed up and took for a test drive and as sure as eggs when I inspected the oilseal it was leaking as in a drip every 20 secs or so.
I must explain a bit about the car here, The car was a normally aspirated 1.9D and the previous owner stuck a turbo 1.9d engine in it because the original engine went for a swim on a well flooded road. So it still had a non-turbo gearbox.
I purchased the new gearbox and thought it best to get a turbo gearbox. It was advertised as a ZX1.9TD gearbox from a parts supplier on ebay.
Well as I said I took it for the test drive and it drives ok and I have noticed it is longer legged going up the gears which was as expected.
I've removed the driveshaft again and measured it up with the old gearbox and there is a noticeable difference in regards to where the shaft seal shoulder stops.
I surmise that the oilseal lip is just bearing on the shamfer on the edge of the seal shoulder on the shaft.
Anyway to cut a short story long, The only problem I've got is the seal leaks so I fashioned up a 2mm spacer ring on the lathe to go behind the oilseal. I'm hoping this will allow the seal to do it's job, I shall see in the morning.
Dont you just love cars..
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