BTR Differential - Output Seal Removal

[Boatbuoy]

Hi All,

A few weeks ago I stumbled across a thread about this, but I've had a good search and can't find it again - so apologies for starting yet another.

I've got the diff out of the car and I'm trying to replace a leaking output seal. The other thread talked about taking off the little brackets that engage into the spoked wheel in the casting (body) of the diff, which I've done. I can get the wheel to rotate by tapping the spokes with a screwdriver and hammer, but I can't see how this is going to allow me access to the seal. Obviously the drive shaft flange/toothed wheel needs to be removed, but does this come off once the spoked wheel is undone or is it push/press fitted onto the output shaft?

Here's hoping that one of you can offer some advice.

Cheers,
Olly

[Boosted Cerb]

Don't adjust the spoked wheel!!!

That's actually adjusting the pretension on the crown wheel bearings.

You need to remove the output flange. It's the same as most drive shafts, it just pops out with a bit of leverage behind it, use a big screw driver to "pop" the flange out.

With the output flange removed you'll see the output oil seal, it's just a normal seal so carefully remove it with something that won't damage the alloy adjuster wheel.

[Boatbuoy]

Damn it, I think I saw a marker for the pre-tensioning on the spoked wheel. It's done less that half a rotation so I hope I'll be able to get it back to 'as was'.

[Boatbuoy]

So, I'm now back onto this. Have I interpreted Boosted Cerb's method correctly in the photos below?





I've applied some gentle pressure but it doesn't seem to be budging. Thought I ought to check before I break something (else!)

Regards,
Olly

[greenracing]

Get some long bolts and tighten them through the output flange until they engange the diff casing, tighten until they are putting pressure onto the diff casing and then use the big lever. Output flange should then pop out. If it still won't budge, put some steel between the diff casing and the ends if the bolts and keep tightening till the bolts push out the output flange. If you have to do it using the second method you may find you need to replace the little spring clip as it will probably get distorted.

[Boatbuoy]

Marvellous, thanks Ryan. I'll give that a go.