Replacing copper disc on output shaft

[Peter Cripps]

A while ago I cleaned and re-annealed the copper disc that seals the passenger side transmission output shaft. Today I decided to do the same on the driver's side, but when I got the disc out I found it was in pretty bad shape. I'm thinking of making a new one, but the only copper stock I can find locally comes in a rather large, and rather expensive, sheet.

Is there any reason I couldn't use brass? I do have some brass shim stock on hand.

Peter

[Huib Geurink]

Has to be red copper to be effective as a seal.
Idea: larger copper ring to seal the outer diameter. M6 copper rings to seal the holes for the two bolts.

[Andreas]

I think the solution with the copper disk is not very good.
I have modified the steel disk. I made it 1 mm thicker and drilled
a groove for an O-Ring.
Also I use for the screws called U-seals ( a static seal under the screwhead)
from Busak+Shamban.
--> No leak anymore

reards
Andreas

[Huib Geurink]

Sounds like a very good solution.

[Andreas]

I have will a look where i have the drawing;

[Peter Cripps]

Good ideas, thanks Huib and Andreas!

To be sure I understand the requirement: the splined inner shaft and the outer hub rotate together, but a solid connection isn't possible because allowance must be made for play in the splined connection. Correct?

So, it would not be a good idea to simply use silicone sealant between the disk and the outer hub?

Thanks again,

Peter

[Huib Geurink]

Right. On most of the S2/3 gearboxes there is play on the splines. Not so on the S1 gearboxes.

The solution of Andreas is really beautiful as it allows the flange and the half axle to slightly move relative to each other. Just do not over tighten the M6 bolts and lock them with Locktite. Any attempt to solve the problem by tightening the M6 bolts will result in broken bolts.

The play on the splines also allows some misalignment of the flange on the half axle. I have never felt that in the steering wheel nor the body. Mass and radius are probably too small to cause any vibration when misaligned.

[Peter Cripps]

OK, all understood.

Since I wanted to get my Fulvia back on the road, I cleaned up the old disc as best I could and put everything back together. I'm not too optimistic about stopping the leak, although I said that about the other side and it's still holding up.

If it still leaks, then I'll follow up on Andreas' solution.

Peter

[FulviaTom]

Hello,

Does anybody know a webshop or company in Holland who supplies the U-Seals?


Kind regards,
Tom

[racing]

some years later B)- enclose the drawings and add. the U-seal from Busak & ...

regards Andreas

Try on ebay usit ring