[SOLVED] How To Replace The Front Axle Pinion Seal?

[attwireless1226]

Hello. So after changing out my transfer case fluid on the TB. I was under the TB and noticed that the front axle piston seal was leaking. Anyone know how I would change this out? Thanks.

[AbsoluteZero]

I was going to change the leaking seal on my 03 but found working from the bottom I couldn't get enough leverage on a 2 ft. breaker-bar to unloosen the pinion nut. I had a few month left on a $100 deductable extended warranty so let the dealer do it.
If you can get the vehicle on a hoist you'll need a way of holding the u-joint yoke and a big socket (don't recall the size) to loosen the pinion nut. The proper way is have an in-lb torque wrench and determine the torque to rotate the pinion shaft before it's unloosen. Mark the relative position of everything.... yoke, nut.... before removing the the nut. Install the new seal, put everything back as marked and retighten until the torque to turn is slightly greater than what you measured before removing the nut. I think the manual showed something like 5 in-lb..... with that said I've changed the rear pinion seal on my 95 S-10 and just returned all components to the marks made prior to disassembly.
The above is not to scare you but unless you have a hoist available it's a tough job just because of clearances.

[attwireless1226]

Originally Posted by AbsoluteZero

...The above is not to scare you but unless you have a hoist available it's a tough job just because of clearances.

Autozone told me how to make a pinion seal tool "remover" myself. It wasn't that hard; pretty much a piece of metal with two holes & a 6 inch bolt. Managed to get it out & replace it without too much trouble.

[attwireless1226]

How to make a tool to remove the front pinion seal: Basically you need a small piece of metal (about 5 inches long), a long bolt (this one is 6 inches), 2 nuts for the bolt. Drill a hole in the middle of the metal (for the bolt), then on the left side drill a hole (using the same drill bit you used for drilling for the bolt) measure 1 inch (mark) then 1 1/2 inches (mark) and drill between the two measurements. Then on the right side 1/2 inch (mark) 1 1/2 inches (mark) and drill between those two measurements. You may have to fine tune the measurements to that it fits for the front pinion seal. Install the bolt, 2 nuts onto the metal. (as shown in the pictures) Take your ratchet and place the pinion tool into the pinion seal (it will align inside the two holes). take your ratchet and go in reverse to remove the pinion seal.