2G W4A32 Output shaft seal removal

[Jovie]

As I am attempting to remove my output shaft seal I cant seem to get it out. I have tried around 4 - 5 different seal puller tools, and I have tried the "screw method" and was unsuccessful. I would like to leave the transmission in the car and I already have decent access to the output shaft seal, wheels are removed, oil pan comes off, transfer case is dismounted etc, I seem to be having an issue getting the seal around the aluminum lip in the output shaft seal housing, how would you guys suggest going about this ?

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[Jovie]

So, I have found multiple threads claiming that you can remove the output shaft seal without removing the transmission, for the w4a32 is it still possible without removing the transmission or is disassembly needed in order to replace the seal due to the aluminum ridge?

 

[dwb]

I've done it on my 1g (manual) with the screw method. The hardest part was removing the output shaft.

Is it just me, or does that seal look like it's glued in?

 

[Jovie]

I've done it on my 1g (manual) with the screw method. The hardest part was removing the output shaft.

Is it just me, or does that seal look like it's glued in?

That would likely be a completely different transmission with a separate design, no ? This car has a w4a32 transmission from the older non turbo awd cars, I would assume that the manual transmission is different due to the many video and pictures i have seen with it. It does not seem to have the same aluminum lip this one does.

 

[dwb]

Yes, completely different trans, but the output shaft and transfer case between the two are very closely related.
I don't see a lip. There's nothing else in there that can be removed to access the seal, besides removing the trans for better access.
Your pic of the seal looks VERY similar to the 1g manual:

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[pauleyman]

The seal looks to be installed backwards. That makes it a little harder.

 

[luv2rallye]

Don't know if this is the "screw method" you referred to but would this motorcycle seal removal technique be of any use?

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[Jovie]

Don't know if this is the "screw method" you referred to but would this motorcycle seal removal technique be of any use?

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That is the screw method I was referring to, I have tried inserting one screw at the top but somehow the screw head snapped off before the seal came out.

Yes, completely different trans, but the output shaft and transfer case between the two are very closely related.
I don't see a lip. There's nothing else in there that can be removed to access the seal, besides removing the trans for better access.
Your pic of the seal looks VERY similar to the 1g manual:

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I do see what you mean regarding the design and whatnot but I believe their may be a small lip preventing removal, I have looked in a service manual or two and it seams like Mitsubishi essentially has you remove this seal last in any procedure. I would like to do it without removing all the gears and whatnot just to keep it simple, Ill likely try the screw method from above with multiple screws and some pb blaster, hopefully this works.

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The seal looks to be installed backwards. That makes it a little harder.

I didn't notice that till now but I do think your correct, It doesn't look as flush as it should, luckily that's on the last guy, unluckily its now on me to remove it.

 

[Talon43219]

Looking at my old automatic case. It appears the transmission will need to be removed along with the gear, viscous coupler and shafts to change that seal. The seal sit against the inner lip and outer shaft that connect to the center differential ect...

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[Jovie]

Looking at my old automatic case. It appears the transmission will need to be removed along with the gear, viscous coupler and shafts to change that seal. The seal sit against the inner lip and outer shaft that connect to the center differential ect...

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Thank you for the pictures, this gives a great visual representation of how it sits, I think ill end up having to drop and pull apart the trans next time I'm back with the car, these W4a32's seem to be designed to be difficult and generally don't have much information apart from the service manual.