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Pelican Technical Article:

Axle Seal Replacement

Steve Vernon

Time:

3 hours3 hrs

Tab:

$2 to $10

Talent:

***

Tools:

8mm triple square, 17mm, 6mm Allen, thin screwdriver, floor jack, jack stands, wheel chocks, safety glasses, lug wrench, torque wrench

Applicable Models:

Porsche 944 Turbo (1986-89)

Parts Required:

Axle seal

Hot Tip:

Make sure the socket is set before removing the axle bolts

Performance Gain:

Power to the road

Complementary Modification:

Change transmission fluid

The axle seals on the 944 are a known area of leaks on the vehicle. The only good thing about this is DIY project is that the seals are not expensive. Additionally, it is not that difficult to replace yourself, if you take your time.

You will need to safely raise and support the rear of the vehicle to replace the axle seals. Please see our article on jacking up and supporting your Porsche 944 for additional assistance.

The axle seals between the transmission and drive flange axles are a known area of leaks.
Figure 1

The axle seals between the transmission and drive flange axles are a known area of leaks. Ours were not too bad, but you should make checking the area around the seal (red arrow) part of your regular maintenance.

You will need to remove the axle (red arrow) from the flange but you do not need to remove the end of the axle from the wheel-bearing hub.
Figure 2

You will need to remove the axle (red arrow) from the flange but you do not need to remove the end of the axle from the wheel-bearing hub. Remove the six 8mm triple square bolts and three half-moon washers. The axle will then separate from the flange (yellow arrow). Tie the axle up and out of the way. Please see our article on axle removal for additional assistance.

Before you remove the axle drive flange you will need to drain the transmission fluid.
Figure 3

Before you remove the axle drive flange you will need to drain the transmission fluid. Make sure to open the fill hole (red arrow) before opening the drain hole (yellow arrow). Please see our article on changing transmission fluid for further instruction.

With the transmission fluid drained (green arrow), you can slide a thin screwdriver through one of the openings in the axle flange (red arrow) and then use a 6mm Allen to remove the flange bolt (yellow arrow).
Figure 4

With the transmission fluid drained (green arrow), you can slide a thin screwdriver through one of the openings in the axle flange (red arrow) and then use a 6mm Allen to remove the flange bolt (yellow arrow).

Remove the long axle flange bolt (red arrow).
Figure 5

Remove the long axle flange bolt (red arrow).

With the bolt removed, you can slide the axle straight out (red arrow).
Figure 6

With the bolt removed, you can slide the axle straight out (red arrow).

Check the axle flange for excessive wear or damage.
Figure 7

Check the axle flange for excessive wear or damage.

Use a seal puller or small screwdriver and remove the seal (red arrow).
Figure 8

Use a seal puller or small screwdriver and remove the seal (red arrow). Use care not to scratch or damage the housing. There is a small spring on the inside of the seal. Make sure to remove it with the seal and that it doesn't stay in the housing.

Clean everything up and install the new seal by gently tapping it in place.
Figure 9

Clean everything up and install the new seal by gently tapping it in place. You can use a 40mm socket to install it. One of the tricks I use it to use a roll of electrical tape and remove enough tape to make an exact fit of the outside diameter of the seal. The seal does not need a lot of force to seat it. You can easily push or tap it in place using the tape.

Make sure the seal sits inside the inner diameter or ridge in the housing.
Figure 10

Make sure the seal sits inside the inner diameter or ridge in the housing. Installation is the reverse of removal.


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