Diff Seal Replacement.

[ChrisR]

Diff is fine but leaking from the housing seal. I will install a new gasket. W.S.M says Disconnect/remove driveshaft. Done.
Remove cover fasteners/nuts. Done (some of the studs came out too).
Pull the rear cover/housing from the main housing. Need comments.
It will move back about 1/4" but no further. What am I missing? I do not want to apply,too much force for fear of gear damage. Do I need to rotate or wiggle the shaft a little to allow the pinion to unmesh?
Is it really necessary to remove the drive shafts 1st? W.S.M. Seems to imply that.
Thanks. Chris

 

[65beam]

Are you talking about the axle seal or pinion seal where the drive shaft connects?

 

[ChrisR]

The Gasket (item 9) between the two housings. Main Axle housing (1) and the Differential housing (10). In my initial post by mistake, I called the Differential housing the rear cover. It should be removed forwards towards the front of the car, so I can install a new gasket. I can only move it about 1/4" forwards.

 

[Barry]

Series Alpines have a drop out style rear axle assembly. As with all drop out style rear axles that I have seen, the axle shafts must be removed before the "drop out" can be removed from the axle housing.

The disassembly process is detailed in WSM 145, Section 10.

http://sunbeamalpine.org/wp-content/uploads/2017/10/10-Rear-Axle-G-1.pdf

 

[65beam]

The differential housing can not be removed without removing the axles from the differential unit.. You can remove the bolts holding the backing plates to the axle housing and pull the axles with the hubs, brakes, etc. as a unit. The axles slide into the gears/ differential unit and prevent it from being removed from the housing. If the leak isn't bad and the housing will move a bit you could do a temporary fix by cleaning and squeeze some RTV sealer between the two housings and then tighten down the nuts. Check the housing vent to make sure it's open .

 

[ChrisR]

Than you all for the clarifications. Another job on the winter list.
Chris