915 transmission seal replacement

[Amstaff]

I have a slight leak in the shifter shaft (for lack of a better term). I searched for how to replace the seal but no luck.

Can someone give me some feedback on the difficulty level to replace the seal?

[JohnJL]

Bump as I am about to embark on the same project. I get transmission fluid through the transmission tunnel out the shifter seal. I ordered and have a 915 front seal and case rebuild seal pack from our host on the bench.

Also approve of the posters choice of breeds, both in aircooled cars and dogs, if amstaff is a reference to staffies.

[LakeCleElum]

I have the same leak and looked it up here previously on Pelican.....A few threads on it and not a big deal to do it with the trans in the car. Be careful to not nick the shaft. Use heat and a small pick to remove the old one.

[DRACO A5OG]

OP, if you are planning to do it in the car, raise the front end high as possible safely. Place a jack stand carefully under gear box remove trans mount to gain more access.

Unbolt the cone set screw on coupler, do not worry you will not lose your shaft alignment.

Use a small screw driver with the end rapped in tape, jam it in there and pull it out carefully as not to nick the shaft as stated above. heat will help too use a heat gun if needed.

use some assembly lube and slip the seal on and it should go on with your fingers.

That should be it, if fluid leaks out, just top it off. That is another procedure but easy enough.

[Amstaff]

Yes, my sister and brother in law are some of the top American Staffordshire Terrier breeders in the US.

Originally Posted by JohnJL

Bump as I am about to embark on the same project. I get transmission fluid through the transmission tunnel out the shifter seal. I ordered and have a 915 front seal and case rebuild seal pack from our host on the bench.

Also approve of the posters choice of breeds, both in aircooled cars and dogs, if amstaff is a reference to staffies.

[Bergo]

I did mine recently before my trip down to Luftgekuhlt, it was honestly a real pain in the rear. I'm fortunate to have a lift in my garage. I believe most of the guides just say "pry out the old seal with a small screwdriver"... good luck.

I ended up using my mid-rise jack to support the engine and trans, unbolted them and dropped it down a bit to improve my angle of attack, there isn't much room between the nose cone and the chassis, dropping it a couple inches allowed me to get a decent enough angle to pry it out. Need to be very careful not to score the shift rod.

[clarkd]

I took some pictures so I could share later after struggling previously with removing this seal.

The shift shaft seal in my mag case 915 was difficult to pull. I separated the handle from the shaft pulling on a pick. I was putting nicks in the housing trying to pry against it with a screw driver.

I finally got the old seal out accessing it with only the coupler cover removed.

Make this simple tool out of a screw driver. I used a grinder with a cutting disc.



Insert the tool into the seal and twist it to engage the hook into the metal of the seal. Pry out the seal leveraging as shown. (The picture is representative since I needed one hand to take the picture) I used one hand to hold the screw driver and the other to pry!



Results

[Amstaff]

Thanks for posting those pictures!

Now I feel comfortable tackling it. I thought the rear housing of the tranny had to come off.

[T77911S]

i had the engine out anyway when I had to replace the one on my 930. I ended up having to take the rear of the tranny off to get it out.

you do NOT want to gouge the tranny case getting it out.

I removed the air vent on top and put a bolt in it, turned it on its end and removed end. no need to drain fluid unless you just want to change it.

[74-911]

This is the procedure I used. I tried a large pick and couldn't budge it so Plan B:

Shift Rod Seal R & R

[brighton911]

clarkd: Nice innovative solution with your modified el cheapo screwdriver. Next time I change mine, your idea will live on.

[T77911S]

you have to VERY careful when doing this.

if you gouge the inside of the tranny where the seal sits you have created a permanent oil leak or if you screw up the outside edge you could damage the new seal going in unless you can file it down.

I bought a used tranny for another car that the PO had gouge the case removing the output shaft seal. had to use epoxy to fill in the gouge. much bigger opening to work with,.

[gptom]

If you are working on a 1st year (72) 915, the seal is replaced from the inside of the transmission

[harvardma]

I just did this today. The modified screwdriver tool worked perfectly.

[DRACO A5OG]

Originally Posted by brighton911

clarkd: Nice innovative solution with your modified el cheapo screwdriver. Next time I change mine, your idea will live on.

+1

[JohnJL]

My car is a 1971 T. For some reason I thought the transmission wasnt original but I am not sure. Its a 5-speed. I already broke 2 picks trying to pry it out. Is this a 1971/72 and if so am I right that I need to take the nose cover off? I dont want to if I dont have to, that seal is dry.

Thanks!

[JohnJL]

My serial number is obliterated. Here's a pic. I admit, I used to rally this car and ran it in Targa Tasmania. I do recall a few scrapes...

[JohnJL]

Little help? Does the nose cover need to come off or can I keep trying to pry the shifter seal off from the outside?

Thanks

[T77911S]

if the tranny is out and you are having a hard time getting it out, like me, then yes, remove the tail. its not a big deal and not worth scratching the case.

if you have oil in it, put a bolt in the vent hole on top, set the tranny on the engine mating surface and remove the tail.
you will need the gasket.

clean tranny very good, you don't want dirt falling inside.
this is why I steam clean my engine vey well before removing.

[reachme]

Went carefully and it took me a few hours but wanted to add to this thread.

Draco above has the best description but was not sure whether to use the tool to catch inside or outside of the seal. (toward or away from shaft).

Then read Bergo and Clarkd showed from inside out and that just did not work for me. The tool would not catch. Maybe like T77911S it is harder on a 930 transmission but same seal.

Here is what I learned:

Have to work from inside the car like Clarkd does, remove driver seat. I have a lift too but the angle is wrong for both insertion and leverage so higher chance for scoring.

Basically the seal has two very thin metal rings (inside and outside) surrounded by plastic. I was not successful trying to grab the seal inner ring either by sliding down the shaft, nor by puncturing the seal and grabbing.
I did the job in 20 minutes once I got a jewelry screwdriver between the top edge of transmission lip and the seal and deformed the seal inward then got the tool in there. (outside in not inside out) That edge of the transmission is after the seal so even if a small scratch it will not compromise the next seal.

New seal is in and tighter than a. . . well let's just say it's tight