BMW ZF5 Output Shaft Seal Driver
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Used to properly seat the output shaft seal to the correct depth within the manual transmission casing
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This is a driver for proper installation of a new output shaft seal. The new seal must be seated to the correct depth within the bore inside the transmission casing.
The bore is 13.5mm deep, with a 9mm deep seal. This tool seats the seal 3mm into the bore. By my measurements, this should provide 1.2mm clearance from the fully torqued output shaft flange, and 1.5mm clearance from the back of the bore. This tool is a recreation of BMW special tool 232300 (83-30-0-491-578), based on the measurements of my own transmission.
This should work for any ZF 5 speed manual gearbox, which were in many BMWs in the 90s and 2000s, including E36, E46, E34 and E39 models. Measurements and testing were done on the ZF S5-31 from my early 2003 330i.
The dimensions are pretty tight, they're pretty critical for this application. Your printer should be able to recreate +-0.1mm dimensional accuracy or better.
I would recommend the following print settings:
- 0.2mm layer height (larger should work as well, but I've not tested that)
- 3-5 perimeters (I used 4)
- 5-7 top/bottom layers (I used 6)
- 30% cubic (or similarly structural) infill throughout
- 100% infill for the first 5-10mm (I did 10, the filament usage is pretty small)
- No supports
- Place the smaller face on the bed