Help needed

[snezza69]

Hello and good moring all,

I apologise for sending this request for advice as I am sure it is covered in the Haynes Manual!

I need to replace the input seal in the front Dif (of a 200 TDi if that makes a difference), is there any thing I need to pull the old one out and anything I should be careful of when replacing the new one?

I seem to have misplaced the manual and will not be able to get hold of a new one for a while!

Thanks!
 :oops:

[snezza69]

OK, found the manual, no mention of the oil seal, in fact it states that you should leave all to do with a diff to an expert.  Fine, but I am sure that the input seal is a fairly easy job (so I have been told)

Started anyway, got the prop shaft off and the split pin out but that big nut is not shifting at all.  Veh is chocked in gear and on the ground (full weight on wheels).  I am using a big bar on the socket (ground clearance permitting)

I NEED AN AIR LINE!!!!!!!!

[Budgie]

Keep at it, it'll give in the end.  

Once you get the flange off then you should only need a screw driver to lever the old seal out. Just remember to put a smear of EP90 around the lip of the new seal where it runs on the flange.

[snezza69]

Thanks Budgie, will keep trying however I am in need of some ramps or a pit as working space is limited.  Will look at getting some ramps tomorrow as it is about time!

Either that or a longer bar!

Oh also will I need a socket or otherwise to push on the new seal? If so what size?

[Budgie]

Oh also will I need a socket or otherwise to push on the new seal? If so what size?

I normally find light taps with a nylon mallet works fine, as long as it has a smooth face so you don't damage the seal.  

[hobbit]

As budgie said if you havn't got the mallet use a piece of wood flat against the seal, and go from side to side to tap it in evenly with a hammer n the wood, as long as it goes in evenly no probs, nice and easy

[snezza69]

Keep at it, it'll give in the end.  

Once you get the flange off then you should only need a screw driver to lever the old seal out. Just remember to put a smear of EP90 around the lip of the new seal where it runs on the flange.

Well had to wait until a neighbour could help and it took me straining on a long bar while he hammered the socket end with a big hammer to break it, but finally it is off.................................

Got the flange off and there seems to be a thin metal spacer in front of the seal.  Tried to prise it out with a screwdriver but it was bending a little.  Do I need to get a replacement?

Does anyone have a diagram of the breakdown of parts for the input shaft of the front diff (I don't imagine there is much difference to the rear), as Haynes dosent have one?