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Old 09-27-2012, 11:44 AM   #1
WVU Mountainman's Avatar
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Pinion seals

Is it possible to change the front and rear pinion seals without an air wrench or gear puller. If so please share your experiences.

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Old 09-27-2012, 12:21 PM   #2
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Just did my front pinion seal last weekend. You will need an impact wrench. The nut was on there pretty good. Took three cycles of the air compressor to finally get it off. If you have the jeep on a lift you might be able to get enough leverage on a breaker bar. I could not get enough leverage with the jeep on the ground.

I did not need a gear puller. I hit it a few times with a rubber mallet with little success. I then took out my riveting gun (same as hitting it with a hammer only more controlled) and tapped it right off in about 5 seconds.

The hardest part was getting the old seal out. I had to bend the flange up almost all the way around before it broke free. Once it broke free it popped right out.

Have fun!


2002 TJ 4.0L Auto 2" Lift
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Old 09-27-2012, 12:33 PM   #3
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Just did my front seal. It's super easy to do. the hardest part is getting the old seal out. I got mine out with a cheapo harbor freight seal puller, a screwdriver and a hammer. You just have to work it for a little bit for it to pop out.

As far as an impact, it sure makes it a lot easier to just zip it off, but it can be done without it. I had trouble torquing the nut because my torque wrench was a tad long and hitting the ground but i eventually got it to spec. Make sure you get a new pinion nut too!
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Old 09-27-2012, 12:45 PM   #4
Knows a couple things...

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While the pinion nut is indeed tight, it's not so tight that you can't remove it without an impact wrench. A breaker-bar will work. Chock the tires since removing/tightening the pinion nuts will try to rotate the axle shafts. Shifting into 4Hi first and keeping the transmission in gear or Park can help keep the Jeep from rolling as you work on the pinion nut. Retighten the pinion nuts to 160-180 ft-lbs. after applying Locktite to the threads.
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Old 09-27-2012, 03:51 PM   #5
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Thanks everyone. Is the new nut necessary? I assume you use the blue loctite not the red?
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Old 09-27-2012, 04:07 PM   #6
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use a nail punch a small hole in the old seal. thread a wood screw in about halfway then use dikes to pull the seal out by the screw.
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Old 09-27-2012, 04:24 PM   #7
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Location: Felton Delaware
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I did my front a few weeks ago ...
I took a 24" pipe wrench on the yolk(wedged against the floor) and used a 2' piece of pipe on the ratchet for leverage.
I used a foam brush and made a paint mark on the nut and just tightened it back up till it lined up
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Old 09-27-2012, 04:28 PM   #8
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Yes on the new pinion nut and yes on the blue Loctite.
2000 Sahara, 3.5" Rubicon Express Lift, 1" spring spacer & 1" Body Lift, 33" or 35" BFG Mud tires, Front & Rear ARB, Rancho 9000 shocks, UCF Ultra High Belly Up, Savvy gas tank skid.

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Old 09-27-2012, 04:35 PM   #9
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i paid 75 to have someone else do it. lol
2004 Sahara kahki D44 4whl disc breaks - OME lift - 31 duratracs - T&T Short arms - Dynomax Exhaust - Bestop Trektop NX - Tube front bumper - Hella E Codes - 15x7 Cragar V5s
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Old 09-27-2012, 07:04 PM   #10
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Since the Jeep is new to me is it worth cleaning up with degreaser and watch it to make sure it is not an old leak? Is the pinion seal just regular maintenance?

It is a 2000 with 40k miles on it.
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Old 09-27-2012, 07:52 PM   #11
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not regular maintenance but not uncommon. take the diff breather hose and blow it out with compressed air to be sure its free of debris. often that gets filled with mud and causes the seals to start leaking.

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