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Here are some photos of the Hummer Differential Output Shaft Seal replacement process.
Dave Breggin '95 Diesel Wagon
Differential Output Flange, Disk Rotor, Seal and O-ring
Closeup of Output Flange, Seal, O-ring, and Flange Nut
Closeup of Output Flange after installation. Use a silicone sealer on the O-ring, and use Red Loc-Tite on the nut.
I have recently install all 4 geared hub output seals on my Hummer (94). They are the same as the military. Do you have the new type seals? The new seals come in two parts, the old type seals have only one part. I will describe how to install the new seals. If you have the old seals, just skip the part that does not apply. The new seals have a dust seal and an oil seal. The oil seal has the metal rim around it and the dust seal is all rubber. All Hummers have to have the oil seal.
Gary 94 Hummer
Any one who has tried to change these knows it a real PIA to press the new seal in without the right tool. Well, after two tries, read two trashed seals, I decieded to lightly taper the outter edge ever so slightly, maybe 1/8" near the base, Cut a price of tubing approx 3/4" that matches the diameter of the seal and used the flang as the surface to strike to press the new seal in. Bingo, went right in without twisting. New flang seal, those little blue seals, new nords for the rotor. On the road again...
Yeah I had to taper the outer edge of the seal myself. After grinding a bit of a taper into it and cleaning it up, I used the diff support bracket and bolts to "press" it in place.
My track has the support brackets that have to be removed in order to get at the output seals. It's a pain to have to remove it BUT it does come in handy to "press" the new seal in place. It presses about 180 degrees of the seal leaving me to tap in the other side as I slowly tighten down the bracket. Once it bottomed out, I removed the bracket and drove the seal the rest of the way home with an appropriate sized pipe coupling.
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