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Manual Transmission Output Shaft Seal Replacement
 
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Pelican Technical Article:

Manual Transmission Output Shaft Seal Replacement

Nick Czerula

Time:

3 hours3 hrs

Tab:

$150

Talent:

*****

Tools:

18mm socket and wrench, flathead screwdriver, E12, 30mm socket, seal puller, 3-jaw puller, floor jack, two jack stands, two wheel chocks, safety glasses, torque wrench

Applicable Models:

BMW Z4 Convertible (2003-06)
BMW Z4 Coupe (2006)

Parts Required:

Manual transmission fluid, output shaft seal

Hot Tip:

Warm transmission for three miles before beginning

Performance Gain:

Remedy a fluid leak

Complementary Modification:

Replace manual transmission fluid

On the BMW Z4 manual transmission equipped models, the output shaft seal can leak over time as the sealing lip wears. You may notice a leak toward the rear of your transmission. Be sure to check the shift selector shaft seal as well. See our tech article on manual transmission selector shaft seal replacing. When looking for the source of an oil leak, always look for fresh clean oil. This will direct you to the problem area. If you see dirt gathered around the output shaft seal and a clean oily area, this indicates a leak at the seal. I would suggest replacing your transmission fluid when you replace this seal.

The seal is tucked away behind the flex-disc and transmission cross member. If checking for a leak, look to the front of the cross member. Inspect the tail shaft of the transmission for signs of fresh oil.

In this article, I'll go over the steps involved with replacing the driveshaft output shaft seal on BMW Z4 models with a manual transmission.

Keep in mind that when your car was serviced before, parts may have been replaced with different size fasteners used in the replacement. The sizes of the nuts and bolts we give may be different from what you have, so be prepared with different size sockets and wrenches.

Protect your eyes, hands and body from fluids, dust and debris while working on your vehicle. If working with the electrical system, disconnect the battery before beginning. Always catch fluids in appropriate containers and properly dispose of any fluid waste. Recycle parts, packaging and fluids when possible. Do not work on your vehicle if you feel the task is beyond your ability.

Vehicle models change and evolve as they grow older, so the vehicle shown in our illustrations may vary slightly from yours. If something seems different, let us know and share your info to help other users. Questions or want to add to the article? Leave a comment below. When leaving a comment, please leave your vehicle information.

Jack up your vehicle and support using jack stands. See our tech article on jacking up your vehicle.

Remove the transmission splash shields. See our tech article on engine splash shields removing.

Remove the flex-disc. See our tech article on flex-disc removing.

Place the driveshaft out of the way, rest it on the transmission cross member (red arrow).
Figure 1

Place the driveshaft out of the way, rest it on the transmission cross member (red arrow). If needed, secure aside using stiff wire. You will have to remove the output flange (purple arrow) next.

Now you can remove the 30mm nut holding the driveshaft flange to the output shaft (red arrow).
Figure 2

Now you can remove the 30mm nut holding the driveshaft flange to the output shaft (red arrow).

Counterhold the flange and remove the 30mm nut (red arrow).
Figure 3

Counterhold the flange and remove the 30mm nut (red arrow). I find placing two bolts back into the flange and using a prybar to counterhold the flange works well. Be careful not to damage the fasteners when doing this, if needed, use spare fasteners.

I like to use a 3-jaw puller (red arrow) to remove the flange from the transmission.
Figure 4

I like to use a 3-jaw puller (red arrow) to remove the flange from the transmission. Install the puller and tighten it until the flange is free.

Then slide the flange off the transmission output shaft.
Figure 5

Then slide the flange off the transmission output shaft.

Now it is time to remove the seal.
Figure 6

Now it is time to remove the seal. I use a seal puller and slowly lever the seal out. You have to stick the puller into the seal and then lever it out. Now be careful not to damage the transmission housing and work gently and slowly (green arrow).

To install a new seal, slide it over the output shaft and press it in by hand.
Figure 7

To install a new seal, slide it over the output shaft and press it in by hand. Then slowly install the seal until it is flush with the transmission housing. You can tap it in using a rubber mallet. Be careful not to bend the seal or seal lip. Install the flange onto the output shaft. Then install the flange nut. Use Loctite 243 on the threads of the nut. Install the drive shaft to the transmission. See our tech article on flex-disc installing for more info. Reinstall the exhaust heat shields and exhaust.

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Page last updated: Mon 12/5/2016 03:02:23 AM