Seals (drive shaft) side of differential
Note: This operation requires a ball joint removal tool. In addition, the lower arm to strut ball joint retaining pins and the drive shaft spring retaining rings must be replaced.
Raise the front of the vehicle with a jack, securely fastening it to the stands under the drive axle, then remove the running wheel.
Drain the gearbox oil as described above in the relevant section.
Remove the locking pin, then unscrew the castle nut of the ball joint of the suspension strut with the lower arm.
Using a ball joint remover, disconnect the strut ball joint from the lower control arm.
Now you will need the appropriate tool to free the inner end of the drive shaft from the differential. When freeing the right-hand drive shaft, a flat steel rod with a bevel on the end can be used. On some models, the left-hand drive shaft may be even more difficult to remove, and a suitable square or hex rod will be required for this job.
Remove the input shaft snap ring from the differential housing. This may cause oil to leak even if it has been drained from the transmission. Suspend the input shaft with a wire or rope so that it does not hang down.
Remove the oil seal from the differential housing using a screwdriver (Fig. 7.11).
Lubricate the sealing lips of the new seal with a small amount of gear oil, then use a metal tube or socket of the appropriate diameter to push the new seal onto the differential so that the outer surface of the seal is flush with the outer surface of the differential housing.
Place a new snap ring inside the drive shaft, then push the VAZ into the differential as far as it will go.
Place a screwdriver on the weld of the inner joint of the drive shaft, but not on the cover, and rotate the VAZ in the differential until the spring retaining ring is in place. Pull on the outer part of the joint to check for engagement.
Connect the ball joint of the suspension strut to the lower arm, then install the castle nut and tighten it to the required torque. Secure the nut in place with a new cotter pin.
Install the vehicle's running wheel, then lower it to the ground and tighten the wheel bolts.
Fill the gearbox with oil as directed in Section 2 of Part A of this chapter.
Main shaft seal (clutch)
Remove the clutch release fork and bearing as shown in chapter 6.
Loosen the bolts and pull the clutch release bearing bushing out of the bell housing. Remove the sealing ring that is between the bushing and the housing (Fig. 7.12).
Remove the old seal from the bushing and install a new one using a tube or chuck. Press in the new seal, being careful, as it can easily be damaged (Fig. 7.13).
Fill the space between the lips of the new seal with lithium grease, then install the bushing with a new O-ring (it must be installed dry).
Install the bushing into the bell housing and tighten the bolts.
Install the bearing and clutch release fork as shown in chapter 6.
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