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I'm trying to get new seals for the front left and right driveshafts into a 92 l series 5 speed dual range gear box. The seals I have have the same numbers on them as the seals they are replacing. They are 50mm OD and a rough measure of the OD on the gearbox is 47mm. There appears to be a lip on the outside. I've had to mangle the old seals to get them out not realising this as the older MY boxes were easy to change this seal. I'm thinking I might have to split the box to change it. If so it might just be easier to change the gear box for a new one. Has anyone got a solution? Dropping the box isn't very appealing to me...

You can split the box to do the front seals, but that to me is the painful way to do them...

What you do is remove the locking tab that holds the bearing carriers in the side of the gearbox. Then you carefully remove them while counting each rotation. Mark the carrier and the gearbox case for their original position then start counting from there.

Once you've got the carrier out you can remove the old oil seal and replace with the new oil seal. Wrap some tape over the output stubs before you replace the carrier with the new seal installed. Then carefully count the number of turns when replacing the carrier. It is hard to tell when you've actually started though.

I've done this twice without any problems. It's a good idea to drain your oil first though

Cheers

Bennie

Cheers Bennie, I hadn't had any luck on my searches. I have one side out... I see now that it's threaded! It took 6 complete turns. I damaged one of the tabs you will see near my thumb but I'm thinking this won't matter.

Did you replace the o-ring whilst you were at it on the retainers? And when I put it back together, what tape are you taking? Electrical tape? And where abouts? Over the drive stub where it would seal or over the splines? Just a little confused on that detail... Otherwise thank you a bunch for your help!

I didn't replace my O rings the first time around. The second time I did from memory.

The tape - electrical over the splines on the output shafts - you want a smooth surface for the new seals to slide over as you replace the bearing carrier

Breaking one of those little tabs doesn't matter really - it'll let the next owner know that someone's been in there before

Cheers

Bennie

I'd recommend replacing the o'rings and would put rubber grease on both the seals and o'rings before putting them back in the box. I'd also recommend doing one side at a time, so as not the get confused or bearings crossed over.

Another point to look out for, is to make sure you put the correct seal in the correct side. There is a left and right rotation on the seal.

Cheers Bennie and Paul, I uploaded the photo's. I thought that's what the tape was for, just thought I'd double check. I did notice the new seals have an L and R stamped on them with an arrow point to the direction of rotation... but only after much study. I'll wait until Monday and get some new O-rings to install them, they have been quite flattened and squared off over the years.