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I'm planning on replacing my left side o-rings tomorrow and was reviewing the service manual tonight. Perhaps the reason why the left side is infamous for leaking is because there is a mount point to the crossmember coming off that side cover. There is no mount point coming off the right side cover. Maybe there is extra stress or vibrations that cause these left side seals to leak after a period of time?? Hmm... stupid design if you ask me. :rolleyes:
Six bolts on left side. Nine bolts on right side. Just the o ring won't do it , you must use a thin film of anaerobic gasket maker on the outer lip of the cover [where the bolts go through].
The two tools that made this job easier were the air hammer with pickle forks and the pry bars. Separating the ball joint and tie rod was a 30 second job with the pickle fork and air hammer. Getting the half-shaft out of the case was a 45 second job with the right size pry bar. Other than that, standard sockets with various extentions and such did the job. When I put the side cover back on I used some anerobic sealer on the flat surfaces to help seal it up, I didn't want to just rely on the o-ring. Also used some liquid teflon sealer on all the bolts holding the cover on. I'll try to put something together for tech tips.
Thanks look forward to your write since this seems to be all too common a problem. A couple questions another forum member said it was not necessary to disconnect the lower tie rod & I noticed you removed the brake caliper was this also necessary. As an aside did you see want the shop manual tells you to remove to do this job.