Note!  We recommend replacing the original leather seal with a rubber one.  There are two choices of seal size:

1. If your drive-flange sleeve measures approximately 1.6" OD, use Federal Mogul seal 5778
2. If your drive-flange sleeve measures approximately 1.9" OD, use Federal Mogul seal 9316.

The process below is the official Jaguar procedure. An abreviated method is below.

Remove and refit

Service tool: Torque screwdriver CBW.548, Hand press SL.T4 with adaptor.

Removing

1. Place car on ramp, set handbrake, chock wheels and raise ramp.
2. Remove nuts securing propeller shaft flange to final drive flange; remove bolts and disconnect propeller shaft.
3. Using torque screwdriver CBW.548, suitable adaptor and socket, check and record torque required to turn final drive flange clockwise through backlash movement.
   NOTE: Set screwdriver initially to 15 lb.in. (0,17 kgf.m.) and increase setting progressively until torque figure is reached at which flange commences to move. Flange MUST be turned fully anti-clockwise through backlash between each check.
4. Mark nut and pinion shaft so that in refitting, nut may be returned to its original position on shaft.
5. Unscrew nut and remove washer and place both washer and nut aside for refitting.
6. Draw flange off pinion shaft using extractor.
7. Pry oil seal out of final drive casing.
   
   Refitting
8. Thoroughly clean splines on pinion shaft and flange, removing all old Loctite. Clean oil seal recess and coat internally with Welseal liquid sealant.
9. Using suitable 'bell-piece' tap new oil seal squarely into position with sealing lip facing to rear. Smear sealing lip with grease.
10. Apply Loctite grade A.V.V. to outer two thirds of pinion shaft splines.
11. Lightly tap flange back on pinion shaft, using wooden mallet.
12. Refit washer and nut removed in operation 5 and tighten nut until it exactly reaches position marked in operation 4.
13. Repeat operation 3.  Torque required to turn pinion shaft through backlash should exceed by 5 to 10 lb.in. (0,06 to 0,12 kgf.m.) the torque recorded in operation 3. If torque is below 25 lb.in. (0,29 kgf.m.),. tighten flange nut further until torque figures is between 25 and 30 lb.in. (0,29 and 0,35 kgf.m.). If, however, torque required to turn pinion shaft exceeds 45 lb.in. (0,52 kgf.m.), final drive overhaul, operation 51.25.19 MUST be carried out.
14. Lift propeller shaft into position, replace bolts, fit and tighten nuts to 27 to 32 lb.ft. (3,73 to 4,42 kgf.rn.).
15. Check oil level in final drive unit and top up if necessary.
16. Remove car from ramp and road test. If final drive is noisy, overhaul procedure 51.25.19 MUST be carried out.

Short Method - not guaranteed, but effective with a newly set up differential

The object is to maintain the precise initial pinion preload after the flange is removed and replaced. The nut must be returned to its exact position on the pinion threads.

1. Drain the differential oil.
2. Remove the driveshaft as described above.
3. Carefully use a punch to mark the face of the nut, the face of the flange, and end of the pinion shaft so that their relative orientation sare well defined.
4. Remove the nut, preferably with a breaker bar so that you can count the number of turns that are required to fully remove it.  If you must use an air ratchet, note how many threads extend past the end of the nut.
5. Remove the flange and old seal.
6. Replace the seal, using a small amount of aircraft type (non-drying) gasket sealer on the edge of the seal.
7. Replace the flange, lining up the axle and flange punch marks.
8. Replace the nut.  Tighten to the exact initial position, matching up the punch marks and the number of turns.
9. Replace the drive shaft.
10. Refill with 80W-90 GL5 lubricant or 90W Moroso Climbing Gear Lube (34800) enhanced with 4-8 oz. of Amalie limited slip additive (505-6775).  If your limited slip seems to be sticking (ratcheting around sharp turns), substitute two tubes of GM additive (1052358) for the Amalie additive.