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Old 08-26-2012, 03:35 AM   #1
Scooby Specialist
Member#: 193412
Join Date: Nov 2008
Chapter/Region: RMIC
1985 pumas.

Default (04 STI) transaxle output shaft seals.

Had a friend pick me up the Axle output seals for my 6 speed and, the dealship gave him the wrong part. Didn't findout that the I.D. was 36mm until after it was installed. When on the passanger output shaft it calls for part 806735290 or 806735300 for the side I need. Just leaked 60 bucks worth in Transmission fluid on the ground due to the mess up.

Here are the part numbers and, once again for the drivers side. This is for MALE OUTPUT SHAFTS

806735230/806735290 - 36 mm I.D. DRIVERS SIDE!
806735290/806735300 - 30 mm I.D. PASSENGER SIDE!

For removal of the sundial (Preload Side) - (Passenger)
I used a coilover lock ring wrench. It rotates out Counter clockwise! Careful not to bust your knuckles open like I did! Drain transmission fluid!
Before loosening, remove sundial crown (14mm wrench) Place a mark on the transaxle and one of the dial to make sure it ends up in the same place. Count how many times you unscrew the dial from the transmission!!! This is very serious for when you put it back together!! Failure to do so can result in blowing up the front Diff due to excess play in the carrier bearing!!! Once sundial is removed from the transmission remove old seal by pushing it inward it pops out from backside! Install new one using your figures only! (Do not force with an object if you do you'll damage the seal and, you'll be starting all over again!) Once that is seated, Clean sundial, check o-ring located on the opposing side of the bearing race. If all is well you are ready to reinstall.
Line up the dial with the mark that you made on the trans. Count how many times it takes to screw in, make sure it comes close or dead on when seated. Tighten and then rotate drivers side wheel clockwise 4 revolutions with the car in neutral. Loosen up sundial, Back off sundial 3/4 of a turn, retighten to line marked, repeat this process 3-4 times. On the 3-4th time your line should be almost dead on from when it came off, Check depth to see if it's about right. Rotate the driverside wheel, It should feel smooth as you rotate it. Put it all back together, Add 75-90 gear lubricant, Clean tools, clean up, Test drive.

Most of you that do this will notice those with high mileage sti's on the deceleration while in gear the transmission chattering sound will almost be gone. Congrats! Your leak is fixed and, so is the tolerance reset on your carrier bearing = longer life for trans =)
Here are some picture references if needed.

Output shaft with wrong seal

Carrier bearing

Sundial O-ring in really bad shape =P
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Last edited by TurboJunkie85; 08-26-2012 at 03:42 AM.
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