R1100S Rear Main Seal - Soda Can Installation Tool

[va011101]

Prepping for this job, I found lots of advice and tips on how to install the rear main seals using shop-made tools and I thought someone might be helped by a step-by-step description of how I made mine, which led to a successful installation.

Tip: the two seals have different outside diameters - the inner is slightly smaller than the outer. Take care that you have the right seal for the given position.

Step 1: Cut the bottom section off one soda can; long enough to fully seat over the crankshaft, but shorter than the depth of the oil filter socket I used to press the seals in. Burnish the edges of the cut edge to eliminate uneven spots. (I used a utility knife blade set in a vice to slice the can and a chrome socket and my fingers to burnish the edges.)



Step 2: Place the cut can over the end of a whole can. Take care that you don’t press it on too hard - it can be impossible to remove without crushing the can. If that happens, you have to start over. I know from experience. I put a little oil on the joint to help it slip off later.



Step 3: Slide the seal over the top of the whole can, with the engine side towards the top. This preforms the seal in the right direction.




Step 4: Slide the seal over the joint to the cut bottom. Make sure there are no rough edges before you do.



Step 5: Remove the cut end, with the seal attached, from the whole can




Step 6: Place the cut end + seal over the crankshaft, ensuring the can extends over the entire shaft, certainly past the crankcase vent. (You can see from the photos I had to press the can into the shaft and expand the concave bottom to accommodate the shape of the shaft.)



Step 7: Use an oil filter socket and a plastic hammer to gently drive the seal in. Go slowly. The inner one will bottom out. The outer seal is supposed to be flush with the crankcase housing.



Step 8: Remove the cut can. As you can see in the photo, the inner seal is fully seated inside the machined recess and is clear of the mid-shaft vent. This vent is notorious for messing up seal installation, which is why you need something to bridge the gap (e.g. soda can). Repeat for the outer seal.



I hope this helps someone with a tricky job - not for the faint at heart, but with care, it can be done successfully by a first-timer!

Andrew Moore
2002 R1100S Prep

[wswartzwel]

Great post!!!

[sgoodwin]

Now comes the put it all back together with fingers crossed part & see if it leaks or not.

[JimMoore]

Great post. Thanks.

[va011101]

Originally Posted by sgoodwin

Now comes the put it all back together with fingers crossed part & see if it leaks or not.

Indeed! It will be faster the second time, right? (!!!)

[Phil K]

Great post!!


Sent from my iPhone using Tapatalk

[brentw1]

hey you stole my patented method,
invented late at night in despiration.
I think I just preformed it on a complete can
and slid it on backwards on the cut can
you could slit the full forming can to fit the install cut can.

[va011101]

Originally Posted by brentw1

hey you stole my patented method,
invented late at night in despiration.
I think I just preformed it on a complete can
and slid it on backwards on the cut can
you could slit the full forming can to fit the install cut can.

Maybe we can license a “special tool” to Beemer Boneyard or EME, consisting of two empty soda cans, and a list of instructions. $50 and split the profits?