Warning: Replacing the seal will knock out the pinion bearing preload, which will then need to be adjusted. The following procedure describes an approximate preload setting using simple tools, after which it is recommended that you have your dealer finely adjust the preload.
1. Remove the final drive unit as described in Chapter 2.
2. Clamp the block in a vise.
3. Measure the pinion bearing preload as follows: place a socket on the pinion nut and use a suitable torque wrench to measure the force required to get the pinion to rotate - it should be approximately 90-120 Ncm. Write down the result.
4. Mark the drive flange nut, drive flange, and gear with alignment marks.
5. Block the drive flange by bolting a piece of metal strip to it. Unscrew the nut, counting the exact number of revolutions required for this.
6. Use a suitable puller to remove the drive flange from the pinion.
7. Wring out an epiploon from a crankcase of the main transfer by means of a screw-driver. Wipe the bearing surface of the oil seal in the crankcase.
8. Apply a small amount of differential oil (see specs) onto the sealing lip of the new oil seal, then push it into the crankcase until it is flush with the outer surface. Use a metal tube or two wooden blocks for this.
9. Reinstall the drive flange on the pinion, then screw on the nut using the marks and calculations you made during the removal of the tag.
10. Now you need to re-preload the gear bearing. Measure the force required to turn the gear (see point 3) and adjust the position of the gear nut to achieve the desired tightness.
1.1 Install final drive unit (see Chapter 2 of this section).
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