Hi Guys,
 
As part of the roadie I need to replace the leaky rear oil seal on the 4 speed g/box.
 
I have a gregory's manual but it just says to take the old one out and put the new one in.
 
Can someone who has done it give me a run down of what's required and if it can be done at home in the driveway or am I better off taking it to a garage?
 
Cheers,
 
Matt 

Matt,
Remove prop shaft & allow to drain (preferably reverse order if g/box has a drain plug fitted). Don't forget to mark prop shaft
& diff flange before unbolting, so can assemble in same position.
Remove seal. It's difficult to lever out because of protruding output shaft. Sometimes driving it further in at one point, will make it pop out diagonally opposite. A method I find works is to drill a small hole(s) in face of seal (it is metal cased under rubber), screw in a self tapping screw, and yank or lever out with vice grips on screw. 
I've had to completely mangle some seals that have been loctited in. Just be carefull to avoid gouging hosing. Better to work at top of seal than the bottom if think you might scratch housing.
Coat od of seal with oil (or loctite if housing surface doesn't look good)
Drive in squarely using a pipe socket or similar, slightly smaller in od than seal (a good place to search is bunnings plumbing section - plenty of pvc pipe sockets/joiners /fittings to choose from, they're cheap & plastic won't damage anything)
 
Cheers, Gregg
 

Matt
 
Just be really careful digging out the old seal as it is super easy to damage the end of the housing. I have a proper seal remover tool you can borrow if you want that will pretty much ensure it comes out without damage.
 
NEW SEAL: There has been an incorrect part listing around for years on this seal which means most places will give you a metric seal and it simply will not fit. The OD is too small and it will literally push in with your fingers ... and fall straight out again.  If the shop tries to give you a rubber coated seal it is WRONG.  It must be a metal outer on the seal.
Better still, using my removal tool will get the old seal out without much distortion so you can take your old seal to a bearing shop and get them to match it to the measurements. I usually get them from Bearing Wholesalers in Barry St Bayswater.
 
Also, if you do it with only the rear of the car jacked up you will lose stuff all gear oil which means you wont have to much around refilling it.
 
G

Thanks guys,
 
I appreciate the help.  I was actually at a dude place yesterday and he happened to have a gearbox lying there and he showed me how to remove it using the special tool.
 
Piece of cake.
 
Gdub, I'll look around to see what the tool costs and let you know.
 
Cheers again,
 
Matt