Seals and Gaskets: Service and Repair

Replacing the primary shaft seal

Note! As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information is always correct.

Primary shaft seal
For cars with early versions of the primary shaft seal (with an outer diameter of 41 mm), see Primary shaft seal 41 mm.
For cars with later versions of the primary shaft seal (with an outer diameter of 44.6 mm), see Primary shaft seal 44.6 mm.

Primary shaft seal 41 mm

Special tools:
999 5687 Extractor 999 5687 Extractor
999 5688 Drift 999 5688 Drift

Removal

Note! Preparations: To remove the transmission, see Removing the transmission Transmission, Removal.

Remove the clutch cylinder

Remove the rubber seal from the clutch cover. Move it inwards on the pipe towards the clutch cylinder.
Pull out the retaining clip locking the quick-release connector on the pipe to the junction.
Remove the adapter. Keep it in a plastic bag to prevent contamination. Install a protective plug in the end of the pipe.
Remove the clutch cylinder.
Clean the mating surfaces in the clutch cover. Check any leakage from the transmission.

Tap in the extractor for the primary shaft seal

Use extractor 999 5687 Extractor 999 5687 Extractor.

Note! The screw and socket must be unscrewed when tapping on the extractor.

Tap the tool into the seal. Tighten the inner socket. Counter hold the outer part at the same time so that the tool expands against the seal.
Tighten the screw in the extractor. Remove the seal.

Installation

Install the new primary shaft seal

Lubricate the lip of the primary shaft seal. Use grease, P/N 1161241-3.
Use drift 999 5688 Drift 999 5688 Drift when installing the primary shaft seal.
Pull the sliding drift sleeve forward. Press the seal into place.
Guide drift on primary shaft. Tap in the seal until the sliding drift sleeve is against the transmission and in the rear sleeve position.

Install the clutch cylinder

Tighten the screws. Tighten to 10 Nm .
Thread the rubber seal onto the pipe with the boot turned towards the clutch cylinder.
Remove the protective plug. Install the junction. Always use a new quick-release connector with a rubber seal.
Lubricate the rubber seal using a drop of brake fluid. This facilitates joining.
Press the pipe into the junction. Lock the pipe using the clip.

Install the rubber pipe seal in the clutch cover

Ensure that the rubber seal locates all the way around.

Note! Follow-up work: To install the transmission, see Transmission, installing Transmission, Installing.

Primary shaft seal 44.6 mm

Special tools:
999 5726 Puller 999 5726 Puller
999 5727 Drift 999 5727 Drift

Removal

Note! Preparations: To remove the transmission, see Removing the transmission Transmission, Removal.

Removing the clutch cylinder

Tap in the extractor for the primary shaft seal.
Use extractor 999 5726 Puller 999 5726 Puller.

Note! The screw and socket must be unscrewed when tapping on the extractor.

Tap the tool into the seal. Tighten the inner socket. Counter hold the outer part at the same time so that the tool expands against the seal.
Tighten the screw in the extractor. Remove the seal.

Installation

Installing the new primary shaft seal

Lubricate the lip of the primary shaft seal. Use grease, P/N 1161241-3.
Use drift 999 5727 Drift 999 5727 Drift when installing the primary shaft seal.
Pull the sliding drift sleeve forward. Press the seal into place.
Guide drift on primary shaft. Tap in the seal until the sliding drift sleeve is against the transmission and in the rear sleeve position.

Installing the clutch cylinder

Tighten the screws. Tighten to 10 Nm .
Thread the rubber seal onto the pipe with the boot turned towards the clutch cylinder.
Remove the protective plug. Install the junction. Always use a new quick-release connector with a rubber seal.
Lubricate the rubber seal using a drop of brake fluid to facilitate joining.
Press the pipe into the junction. Lock the pipe using the clip.

Installing the rubber seal for the pipe in the clutch cover

Ensure that the rubber seal locates all the way around.

Note! Follow-up work: To install the transmission, see Transmission, installing Transmission, Installing.