I am getting ready to change the two opposing oil seals on the shaft between the gearbox and the differential on my beloved 1986 Volvo 340DL 5 speed.
These separate the ATF in the gearbox from the gearbox oil in the differential.
In between the two, it leaks some oil, failing the inspection.
The problem now is, that I've been here before. Half a year ago, I changed them for the same reason and the leaking just became worse.
I do have the special tool from Volvo to seat the seals at the right height (9995908), but I wasn't really able to use it last time (was also under a lot of stress to get it done...)
I have the Haynes workshop manual and the Volvo greenbook, but my transmission is of course slightly different than in the pictures...
Here are some pictures from when I did it the first time:
https://imgur.com/a/O5a6iqx
As you can see here, my differential is different from the one in the greenbook, mine only has one 'hole' in the casting:
https://imgur.com/a/79627RE
Here is the relevant page from the greenbook describing the use of the tool
https://imgur.com/a/NvZvI7l
but I can never push that tool so far into the hole, there is some stuff in the way:
https://imgur.com/a/ieodNBw
If I recall correctly, the diameter of the tool was even bigger than the hole; so it couldn't fit in at all. Not entirely sure anymore though...
When I took it apart, the seals also seemed to be very near to the top of the casting, not at all at the depth where the tool would set it:
https://imgur.com/a/cIoOWdY
So either I cannot use the special tool for this job, but how then can I do it properly?
Or the seals just came to the top while taking the two halves apart? Do I need to somehow remove the "stuff" that is preventing me from pushing the tool in (if it even fits)?
Does anybody have experience with this job and can share some tips/picture on how to use the tool properly and prevent me from having to do this a third time?
