Since you put this in the "All" category I would not have found it unless it made it to the front page.

I don’t know how much of the write up in the FAQ belonged to me but the angle iron tool photo was mine and I am glad it helped. It is not the first time I use the garage floor as tool holding aid. I used an available 12 point socket to remove the pinion nut with a 4 pipe as an extension. Maybe the 12pt socket was an advantage in this case because I was able to get to the correct angle in the narrow space between the floor and the underside of the car using my pipe extension.

In my 940, I had a separate dust cover that gets destroyed during removal. Once I was able to bend a lip up enough I grabbed it with vice grips and levered pieces out against itself to keep the tool off the casting. My dust cover came out in three pieces. I pushed the seal in slightly to break the adhesion used a taped screwdriver with a bend on the end to pull it out.

The replacement after market seal from Swedish Engineering had a one piece dust cover and seal. I gently tamped it in place with a piece of wood. The key is using lots of surface area and gentle taping. The flange on the metal dust cover sits on the casting surface and the seal lip ends up where it does when the flange is seated.

I borrowed a dial indicator torque wrench from work to torque the nut to 150. I could not get more than that. Little room for leverage and not fun.

Difficulty factor, well I discovered a pinion seal leak in another 940 and one in the 240 and I decided to just check fluid level for a while. I’d say the second time around will be a little easier then a timing belt change considering there is less fussing just to get to it.

Tom