I am in need of some information about the replacement of pinion seal on 98 xj8 base model. Mechanic has tried to replace just the seal and it is not sitting correctly, the TSB says replace with flange yoke but what is different about the yoke? The yoke with nut and seal is minimum $375.00.

 

Had my seal done on my 2000 for $550 w/labor about 3 yrs ago. So that cost you posted, plus your labor will be about right.

 

I'm willing to bet that the real leak is where the fluid travels up the splines and leaks out from under that pinion nut. I've repaired these leaks several times but cleaning up both the male and female spline mating surfaces, applied silicone sealer just where they both start to meet and slide them together and torque the nut. Sorry, that's the best way to describe it, now I need a cigarette. The problem lies with the metal makeup. (Forget the terminology) I'm pretty sure the pinion is softer than the driveshaft stub and then it twists or wears more so than the stub then clearance is formed.

 

It is usually possible to replace the seal only. The Workshop Manual advises to lightly lubricate the outside diameter of the seal before installing it in position.

Correct seal location is said to be "automatic." You are to place the seal in position, install the flange and nut, "Ensure that the seal, Ryton ring and backing are aligned and in contact with each other," then pull the flange and seal into place by tightening the nut. "Do not hammer the flange." "Rotate the pinion prior to final tightening."

I haven't tried Addicted2boost's tip about adding some sealant on the pinion shaft and flange splines, but it sounds like it might be worth a try.

Regarding the TSB you mentioned, I assume it was referring to the 14U differential with the integral flange/seal that must be replaced as an assembly. I don't know if a workaround is possible.

Cheers,

Don