Differential Side Seals

[asiab3]

Lighting is funny that way… Your installation looks fine; I use the 46mm socket and wood dowel technique myself.

I've had two of those blue circlip oil caps leak on different cars in the last few years, so I have started to use a THIN application of non-hardening sealer (Kuril is one) on their edges before installing them. Hardening sealers and gasket makers are a pain to clean up, but I've used them in a bush fix before too…

Robbie

[kreemoweet]

And YES INDEED that installation was a pain!

I commend unto you the use of the threaded hole in the differential output shaft (M10 x 1.5 as I recall) to press
the seals in instead. You'll need a length of M10 threaded rod and a suitable assortment of big washers, sockets, and
whatnot to rig up a pressing tool (it's been a number of years since I last did this so I can't be more specific).
The seals just meekly slide evenly into their holes as you tighten the nut, without incident. Personally, I simply
hate banging on any part of my Bus with hammers and such.

[vwlover77]

Oh, now you tell me!

I saw the threaded hole and wondered about that, but wasn’t sure where the thrust load from seating the seal would be applied inside the transaxle. I didn’t want to damage something or pull out the shaft!

[vwlover77]

The Bus is back on the road! My FLAPS was able to find a sleeve to slip onto the drive flange to provide a new, smooth surface for the seal lip (but kinda pricey at $45), and new plastic locking plates. I also replaced the cap seal on the passenger side. No seepage yet, but not many miles yet either. We shall see!

[Amskeptic]

The Bus is back on the road! My FLAPS was able to find a sleeve to slip onto the drive flange to provide a new, smooth surface for the seal lip (but kinda pricey at $45), and new plastic locking plates. I also replaced the cap seal on the passenger side. No seepage yet, but not many miles yet either. We shall see!

Congratulations.
Can you imagine doing this job out in the wilds, "gee, I don't get to *leave* until I finish this job"?
That is precisely why I do it out in the wilds. It keeps me focused and alert.

So the leaky seal was already a sandrail seal? Did it leak at the lips or the circumference? Was the drive flange loose on the differential splines?
Colin

[vwlover77]

Can you imagine doing this job out in the wilds, "gee, I don't get to *leave* until I finish this job"?
That is precisely why I do it out in the wilds. It keeps me focused and alert.

So the leaky seal was already a sandrail seal? Did it leak at the lips or the circumference? Was the drive flange loose on the differential splines?

I cannot imagine doing this job in the wilds. Especially because it tool my FLAPS 5 days to get the sleeve and locking plates!

Yes, the leaky seal was one of the wide ones (photo below). Is that what makes it a sandrail seal? No leakage at the circumference as far as I could tell.

The drive flange was quite snug on the splines.

Interestingly, mine had no dust seal but did have a "washer" between the circlip and drive flange.

[jalabert]

And YES INDEED that installation was a pain!

I commend unto you the use of the threaded hole in the differential output shaft (M10 x 1.5 as I recall) to press
the seals in instead. You'll need a length of M10 threaded rod and a suitable assortment of big washers, sockets, and
whatnot to rig up a pressing tool (it's been a number of years since I last did this so I can't be more specific).
The seals just meekly slide evenly into their holes as you tighten the nut, without incident. Personally, I simply
hate banging on any part of my Bus with hammers and such.

Perfect, thank you very much. I can confirm your memory is bang on, it's M10. I used a 130mm coach bolt, a washer and the 46mm socket, and it worked like a dream. Same thing works perfectly for pressing the flanges into the new seal. Much swearing saved, and instead a smug feeling of satisfaction that demands a beer.

[Amskeptic]

pressing the flanges into the new seal. beer.

I am confused here. Are you speaking of the flanges passing through the seals as they are pressed onto the splines?
Colin

[jalabert]

pressing the flanges into the new seal. beer.

I am confused here. Are you speaking of the flanges passing through the seals as they are pressed onto the splines?
Colin

Yep, that's the one...

I had one deep seal, and one sandrail type. I can't imagine either of them will be fun to remove, here's hoping for a decade or two of leak free service...

[Curtp07]

Awesome write up thank you!