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Author Topic: Diff Pinion Oil Seal Change  (Read 8076 times)

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Marks DTM Calib

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Diff Pinion Oil Seal Change
« on: 08 September 2006, 14:33:21 »

The following is courtesy of Matchless with pictures supplied by seprim  :y

Tools required: 3 leg puller, 30mm deep socket, breaker bar or T bar plus extension pipe, centre punch, hammer, various spanners, suitable large socket / piece of tube / old bearing ring etc to drift new seal in and an 8mm allen key (or could be T50 torx) to check the diff oil level

Raise rear of car on ramps or jack up and support on stands. In either case chock both front wheels, front and back, and make sure the care is stable. You will be using considerable force so the car must be well supported.

This is often what you will be greeted with!



Mark the pinion drive flange and rubber coupling with spray paint etc to ensure you can put it back in the same place (optional but, good practice).



Un- bolt the propshaft rubber coupling from the pinion flange. Use a pry bar or large screwdriver to free the propshaft coupling from the pinion flange, note that the propshaft has an alignment spigot which engages with the pinion shaft so the propshaft has to be moved forwards about 1" / 25mm before it comes free.



Tie the propshaft out of the way.



Clean around the pinion nut and flange then use centre punch marks to mark the nut position, two dots on the nut and two on the flange. Do this carefully and very accurately, the nut sets the pre-load on the pinion shaft taper roller bearings, we cannot easily re-adjust the preload so must return the nut to its exact position.



Now undo the pinion nut, it will be very tight. You could bolt a length of angle to the pinion flange to help hold it still or get a helper to stand on the brake pedal.
Count the number of turns or flats needed to remove the nut, it is not essential but help with confidence when replacing the nut later.

Mark the relative position of the pinion shaft and flange, lightly centre punch the crest of one spine on the shaft and the adjacent valley on the flange.

A 3 leg puller is now needed to pull the flange off the pinion shaft. DO Not try hitting anything with a hammer, you will only ruin the diff bearings.

If you do not have a puller, you can re-fit the nut to the diff flange and use the prop section (without the rubber donut) and three of the nuts/bolts, to pull the flange off.



Almost off



Clean around the oil seal and rush off to get a bowl etc to catch the oil that is now dribbling out.



Hypoid oil stinks as you have now found out.
Note where the seal is positioned, flush with the diff case or slightly recessed.

Use a large screwdriver to lever the old seal out. Take care not to damage the shaft or casing in the process.

Insert the new seal. Easier said than done as the seal has an external lip which fits into a recess on the back of the flange, presumably to protect the main oil seal lip from dust & grot. I found an old piece of steam pipe which was the perfect diameter to drift the seal in, an suitable BIG socket, old wheel bearing ring etc would do.
If you cant find anything of the right diameter then a piece of hardwood can be used if very careful or the old seal!.



Start by trying the engage the seal by hand then use the hardwood as a protector and gently tap the seal home, tapping opposite sides at first, trying not to let the seal tip over. Once engaged in the bore, work around the seal tapping it in little by little until fully in place.

Clean the seal lips then wipe a little diff oil over the lips and the surface of the flange. Align your punch marks and replace the drive flange, it will only go on a little way then you have to re-fit the nut to continue pulling it into place. DO NOT try hitting it.

There will seem to be loads of play in the pinions shaft, don't panic, this will disappear as the flange is pressed home. Keep looking for you punch marks as you tighten the nut and finally align the marks exactly. (this is when it helps to have counted the number of turns and flats needed to remove the nut). Note, it will be bloody tight!

Replace the propshaft and tighten the bolts to the correct torque. If you have any doubts about the self-locking nuts then get new ones or use Locktite.

Check the oil level in the diff and top-up, note that limited slip diffs need a special oil.

Return car to ground and job done. All that remains is to put overalls in washing machine and discover that the smell of Hypoid oil will not wash out....of your overalls or the washer!!

Diff Pinion Seal - 24435952
« Last Edit: 07 June 2016, 12:20:26 by Marks DTM Calib »
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