So, I'm working on a /6 64 val sig 200 conv and trying to get all of the leaks fixed before I start to work on the body & paint. Today my problem is with the rear end. I jacked the car up and layed under it yestereay and started scraping the pumpkin getting all of the old crud off. Obviously this has leaked for a while. The entire pumpkin & u joint was caked with old hardened gear oil. Now I have scraped most of stuff off and it looks like someone took a chisel to the plug to get it off.

Question:

So I'll probably need to get a new plug. Can these things be bought new or do I have to make a trip to the ecology center and pull one myself? Also, what about the plug gasket, are they still available?

Next, I can't seem to see where the thing was leaking (cover gasket or from near the flange where the driveshaft connects).

Question:

Should I just replace the flange seal and the cover gasket along with the plug and plug gasket just to be safe?

I have never worked on a rear end before but the posts I have read make it seem not that hard. Is a seal puller puller a good idea?

Thanks

James.

I would go to the wrecking yard a get a replacement plug, I bet you could grab the whole cover & plug for the same cost.
The plug should have a plastic washer under it which can be reused with a little sealer to prevent leaks. Be sure the mating surface is clean and flat.

As for the leaking, sounds like the pinion seal (yoke seal) is the problem.
These can be replaced but be ready to deal with a big & tight nut that holds that yoke on. You do not need a "seal puller" to get the seal out, a hammer and a screwdriver will do the job.
DD

Thanks, that's what I thought it was due to the amount of old gear oil all over the pumpkin.



Any idea what size this nut is and how deep do I need the socket to be if I can get one in there?

What does it need to be torqued to when tightening?

James.

When you are getting the cover, loosen the plug before you pull the cover off.

You don't need a deep socket to get the pinion nut off. It takes some manhandling, but it's not that hard.

I just did mine and mostly I worried about messing something up. Other than a screwdriver, I didn't need to worry.

You may need to get creative in order to generate enough mechanical advantage to loosen the nut.


Good Luck

John Killin