Most of the time, a pinion seal will be replaced when it leaks. Differential fluid is very thick, so a leak will usually begin with a slow seep or dampness around the rear differential housing. If there is wetness or dripping fluid, that is a fairly advanced leak.
Most four-wheel-drive vehicles also use a front differential, which also has a pinion flange and seal. For the most part, the construction and the procedures to replace it are the same as for the rear pinion seal, and the cost of pinion seal replacement is comparable. The front differential does much less work generally, though, and the front differential seal tends to last much longer.
Cost of Pinion Seal Replacement
On average, for most vehicles, it costs about £110 to replace a rear pinion seal.
The cost does vary depending on the type of vehicle and model, the type of parts to be used, and the labour charge, which is dependent on the location and skills of the auto shops.
Below are some specific rear pinion seal replacement cost estimates using common vehicles as examples. The labour rate will be set at £70 an hour to complete the illustration:
- For a 1998 Chevrolet 1500, the labour time to replace the rear pinion seal is estimated at 1 hour. A non-OE seal costs about £18, making the total cost about £90. There are actually four different rear differentials that might have been used on this vehicle. But the costs for the pinion seal vary only a small amount between the different versions.
- For a 2010 Jeep Wrangler, the labour time to replace the rear pinion seal is estimated at 0.7 of an hour. A factory pinion seal costs about £20, and a non-factory seal costs about £8. The total cost to complete the job would be about £70 using factory parts or £55 using aftermarket parts. There are two different rear axle options, but the costs are about the same either way.
- For a 2008 Nissan Frontier, the labour time to replace the rear pinion seal is estimated at 1.3 hours. An aftermarket seal costs about £12, making the job cost about £100.
- For a 2009 Ford Explorer, the labour time to replace the rear pinion seal is around 1 hour. A non-OE seal costs about £8, making the whole job cost about £80.
PRO TIP – In all cases, a small amount of gear oil would be needed to top off the differential. It is very common to replace the seal in conjunction with a differential service, replacing all the fluid. Usually, it will take half an hour of labour plus fluids; costing around £45 to £90.
Rear Pinion Seal Replacement
On a differential, the power input from a driveshaft begins with the pinion flange, which the driveshaft bolts to. The pinion flange is splined and bolted to the pinion gear, which transfers power to the ring gear and the two axles driving the wheels. The pinion seal presses into the differential housing, and the lip of the seal bears against a machined surface of the pinion flange, sealing oil into the rear of the differential.
Replacing the pinion seal is usually a matter of unbolting the driveshaft and removing the centre holding bolt, then using a puller to remove the pinion flange. The seal can then be pulled and a new one installed.
What Else Can Go Wrong?
One of the simplest things is the pinion flange that the lip of the pinion seal bears against. It’s a machined surface, and if it shows any wear or imperfections, a new seal will generally not last long. The pinion flange is ordinarily replaced if it shows any signs of problems.
The second problem is more involved. Sometimes, a pinion seal will fail because of play in the pinion gear itself, which is held in place by a crush sleeve and the pinion bearings.
If there is any looseness or play in the pinion gear, the usual remedy is a full rebuild of the differential. The pinion gear, however, doesn’t require just a lack of looseness but that the bearings are tight enough to hold the gear stable under turning forces.
The tightness of the bearings is called their preload. The complication to that is that the pinion gear bearing preload is properly set and checked with the ring gear removed. Because of this, it’s not usually possible to check the pinion bearing condition without disassembling the differential.
Another issue is the rear crush sleeve, which assists in the setting of pinion preload when the pinion flange is tightened down. Going strictly by procedure, the crush sleeve is a single-use part and should be replaced before the pinion flange is torqued back down.
But replacing the crush sleeve and setting the pinion preload also requires removing the ring gear and disassembling the full differential. This is the reason why manufacturers don’t typically supply labour times or procedures to replace the pinion seal itself.
In practice, however, it is usually acceptable (though not ideal) to install a new pinion seal, leave the old crush sleeve in place, and torque the centre nut of the pinion flange to specifications without measuring the pinion bearing preload.
In almost all cases, about an hour or less.
It depends on how bad it is. Gear oil is very thick and tends to leak slowly. Small leaks or seeping can be almost inconsequential as long as the fluid level is maintained. If gear oil is actually dripping from the housing, that would be more urgent.
The seal is lubricated with gear oil, so any dirt or contamination in the fluid can cause it to wear. Running in a dusty environment can also cause wear, and any looseness in the pinion bearing can cause it to leak as well.