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Rear Main Seal Replacement - In Car - My How-To

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(@Chad McLeish)
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In the interest of helping someone else I wanted to contribute by sharing my experience.  I purchased a 1949 Commodore 6 with a 262 engine that lost around a quart of oil per hour.  So I ordered the Best Gasket rope seal set, a Sneaky Pete tool set, and a Best Gasket oil pan gasket, and started reading on these forums.  There was discussion but nothing that made me feel a whole lot better about tackling the job.  An old-time mechanic in my car club who did this job on a Hornet told me he pulled his engine to do the job and it still leaked.  He couldn't believe I would get the oil pan off, let alone succeed.  I didn't have much confidence, but what I did have was faith in the man upstairs that He would help me get the job done!

My garage has the advantage of having a 2-post lift and it was a definite advantage for this job.  Lots of guys do this lying on the floor but I would have been up and down 30 times once I explain why.

First, unbolt and drop the center steering bracket and the tie-rods and let them hang down.

Next, take off the cover plate under your flywheel and remove your dipstick.

Next, unbolt the oil pan and attempt to remove it.  If the oil pan will not clear the flywheel, simply use a small crowbar to carefully rotate the flywheel using its teeth.  The crankshaft will turn until the oil pan clears.

Next, I cleaned up the gasket and goo from mating surface of the block.

Next, unbolt the rear main bearing cap and use a slide hammer to remove it.  I had to custom make a 1/4" steel plate and use two long bolts to bolt to the bearing cap for a place to bolt my slide hammer to the bearing cap.

Next, put the bearing cap in your vice and clean up the old "rope channels" cut into both sides of the bearing cap.

Next, remove your old rope seal from the top of the crankshaft.  Mine simply pulled around with needle-nose pliers, but if not then use the Sneaky Pete tool that screws in.

Next, pull or scrape out the bottom half of the rope seal from the bearing cap in your vice.  Carefully clean out the groove with brake cleaner spray and a clean rag.

Next, use a gasket adhesive to glue your bottom half of the rope seal into the groove in your bottom bearing cap in your vice.  This keeps it from spinning while the engine runs in the future.  More on the bottom bearing cap work in a few steps.  Do not worry about trimming or pounding the seal yet. 

Next, this is where it gets interesting.  I have no idea how anyone gets the Best Gasket rope in the top without destroying it.  I fought with it for 2 evenings with no luck. It is much bigger than the old one that came out of mine.   So what I did was, using a sharp Exacto-knife, I carefully trimmed about 1/3 off of what would be the back of it that goes against the opposite side of the crankshaft.  There was still plenty of seal left to fill the gap.

Next I coated that top rope in engine break-in lube (heavy oil would do the job too).  I used the Sneaky-Pete jaw & wire, put it on the rope seal and pulled the wire through with the seal oriented with the open side of the jaw facing the crankshaft.  Using one hand with a small crow bar, I turned the flywheel one tooth at a time with careful, easy pressure on the Sneaky-Pete wire.  Do NOT pull too hard or you will have a problem and have to order a new seal!  It took probably 15- 20 minutes or so to carefully pull it through, and I had to "smoosh" the seal back into shape as it went into the gap probably 10-15 times as I went.

Next, after you work the top seal through, leave the ends with about an inch of rope on each side. Now, I was anxious about all this because the rope ends looked like a real mess and I had no idea how I was going to trim them neatly.  So I used a small punch and started pushing the loose ends into the opening, and packed the openings as tight as I could get the rope material in there.  Now- how to trim the excess?  Well, that little knife they send you in the Best Gasket kit is both highly flexible and sharp!  So I carefully and successfully trimmed the ends flush.  Alright!

Next - back the the bottom bearing cap in your vice.  My first thought was, "this rope seal will compress on the crankshaft when you bolt the cap in."  This was a very WRONG assumption.  So here is what I did - I coated all the crankshaft bearing and seal surfaces with assembly lube oil.  Then I used a really big socket from my 3/4" socket set that was the same diameter as the seal, and I started pounding the seal into the cap and trimming the seal as it pushed out the ends.  This was a LONG process, because I would periodically test the cap against the crankshaft.  What I looked for was to get even oil impression on the entire seal surface and the bearing surfaces.  Wipe off the oil and repeat.  Repeat.  Repeat.  Pound some more, trim, re-oil and repeat.  This is slow and careful work!  Did this MANY times.  No one talks about this.

Once you get that to where you get equal oil touching your bearings and your seal surface, do a final cleanup of the block surface where the cap slides in.  I cleaned the sides with brake cleaner because that is where the mop-string rope will go.  Clean the sides of the bearing cap where the "rope grooves" are, with brake cleaner and clean rag.  Bolt in your bearing cap and torque it to specs.  I believe it is 80 foot-pounds from memory, but the shop manual will confirm this.

Next, take one piece of the mop string/rope from the Best kit, and coat about half of it with your choice of sealant.  I use Permatex Right-Stuff.  Then stuff the rope into the sides of the bearing cap and pound in with a small punch.  Trim off the excess.  Repeat on the other side.  

Next, clean out your oil pan like new, and clean out your oil pickup screen like new.  Goo your gasket on, with the o-ring at the oil pump tube as well, and bolt the pan back in place. 

Finally - Bolt your center steering bracket back up into place, refill with oil, put your dipstick in and check the level!  

Viola!!  This is how I accomplished the job.  People may criticize or applaud, but that is what I did. Hopefully it helps you.
  
 

     


 
Posted : 05/11/2022 1:45 am
(@wendleton)
Posts: 12
Active Member Registered
 

Chad, Great write up and explanation of a very dirty job. I see you did not loosen any other main caps. Did you try that?  What was your success? How long has it been back on the road? Thanks, Fred


 
Posted : 05/11/2022 4:16 am
(@Peter Kurzenhauser)
Posts: 0
 

Chad. Thanks for that write up. You explained it perfectly, especially the part about having to fit and test and refit and retest about 30 times!  The manuals conveniently omit this very tedious and frustrating part of the job.  Another big reason not to do this job laying on your back is that you’ll end up with lots of oil in your face and the front of your shirt. I’ve done this job too, and I wouldn’t even think about doing it without putting the car up on a lift.  

Also curious about whether you loosened the other main bearing caps.  When my brother and I did the job on a his Studebaker Hawk, we loosened them to allow the back of the crank to drop down a half inch or so.  


 
Posted : 05/11/2022 11:36 am
(@Chad McLeish)
Posts: 0
Topic starter
 

Thanks Gentlemen - I did not loosen the other caps.  I was thinking that would require removing the transmission?  Maybe not?  There was another discussion on the "open" forum about loosening the back plate on the engine but I could not feel or locate all the bolts, let alone get a wrench to them all.  


 
Posted : 05/11/2022 12:50 pm
(@Chad McLeish)
Posts: 0
Topic starter
 

I have been driving the car for a week now with the new seals.  So far it is not leaving any drips anywhere in the driveway.  I would imagine it will seep some because as Doug Wildrick points out, the old surface of the crankshafts have minor pitting due to age and wear.  My crankshaft has some pitting on that surface where the seals are.  If a person were patient, this may be carefully corrected with JB-Weld epoxy and a Dremel + polishing wheel.  I had no desire to fool with it.  If it seeps some, I don't mind.  The quart an hour was a real nuisance.   

One thing I did NOT do, is to offset the ends of the seals from the mating surfaces.  The old original seals in mine were offset so the ends met in the 5-o'clock position on the crank, and there was probably a 1/2" gap due to old age shrinkage or who knows why.  It leaked like a sieve and did not have a chance.  It was a crop-duster.

There was also a lot of discussion about using Dodge 318 engine neoprene seals from early 1970s engines, with mixed results.  They could work just fine as long as you carefully shim them to compress the seal against the crank.  I think a lot of guys just want to treat these seal installations like modern cars, but these tolerances require more trial and error.  There were 2 sizes of the neoprene seals - I would get the larger of the two and adjust from there.

The other idea I had for the bottom bearing cap seal was a little off the wall... Dentists use a sort of soft putty epoxy mould when they make crowns for teeth.  I was tempted to ask my dentist (who is also a farmer and a good guy) to buy some from him to form a mould of the seal against the crankshaft, and then form one from silicone in that exact shape.  But, after pounding the rope it formed a nice, wide seal surface that seems alright. 
     

  

  


 
Posted : 05/11/2022 1:26 pm

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