Tools & consumables
- Basic hand tools: metric socket set, combination wrenches, screwdrivers, breaker bar, ratchet, hex keys.
- Torque wrench (appropriate range for axle/gearbox bolts).
- Seal puller and long-reach hook tools.
- Bearing/gear puller and slide hammer (for drive flange/gear removal).
- Drift set, brass/nylon punches and a dead-blow hammer.
- Seal driver set (correct diameter) or suitable pipe/wood block as improvised driver.
- Arbor press (if available) or press-fitting tooling.
- Snap‑ring pliers.
- Hydraulic line wrenches and plugs/caps for hydraulic fittings.
- Hydraulic jack and secure stands / engine hoist or lifting device (as required to support loader components).
- Oil drain pan, funnels, clean containers for old oil.
- Cleaning solvent, lint‑free rags, wire brush.
- New gearbox oil (OEM spec), replacement oil seals (correct part number), replacement O‑rings, gaskets, and thread locking compound if required.
- Thin film of gear oil or assembly grease.
- Personal protective equipment (safety glasses, gloves, boots, hearing protection).

Safety & precautions (must follow)
- Park machine on level ground, lower loader arms to the ground, apply parking brake and chock wheels/undercarriage.
- Shut off engine, remove key, and disconnect negative battery terminal to prevent accidental start.
- Relieve hydraulic pressure: cycle controls with engine off per OEM procedure and cap/plug opened hydraulic lines immediately to avoid contamination and fluid spray.
- Support any components or loads (axles, lift arms, attachments) with appropriate stands or hoists — never rely on hydraulics alone.
- Use caution with hot oil and surfaces. Dispose of used oil per regulations.
- Keep work area clean; shield hydraulics and gearbox openings from dirt and moisture.

Overview of procedure
1) Identify exact seal and location (output shaft seal, input shaft seal, final drive seal). Obtain OEM seal part number(s) and lubricant specification. Do not proceed without correct replacement seals and oil.

Step-by-step procedure
1. Prepare machine
- Park, isolate electrical system, relieve hydraulic pressure, chock and support machine.
- Clean area around gearbox to prevent contamination entering during disassembly.

2. Drain gearbox oil
- Place a drain pan under the gearbox drain plug. Remove drain plug and allow oil to drain completely.
- Inspect oil for metal debris (may indicate bearing/gear damage) and retain oil sample if diagnosing failure.

3. Remove external components blocking access
- Remove wheels, tires, drive flange, sprocket or hub as necessary. Use torque tools and note bolt orientation and positions.
- Disconnect drive couplings, speed sensors, parking brake linkage, and any hydraulic lines or hoses attached to gearbox housing (cap/plug lines immediately).
- Mark alignment positions of coupling or flange to the drive shaft to preserve orientation if reassembly requires.

4. Support and remove gearbox or access cover
- If the seal is accessible by removing a cover or housing plate, unbolt and remove the cover. Keep bolts in order.
- If the seal is behind a driven gear or flange, remove that component using puller/slide hammer. Use heat (careful) if a flange is tight, but avoid overheating seals/bearings.
- For major assemblies, support gearbox weight and remove mounting bolts to drop gearbox out of machine if required.

5. Expose shaft and seal
- Clean surrounding area, then remove any retaining rings or circlips with snap‑ring pliers.
- Inspect shaft and bore for scoring, corrosion, or burrs that will damage new seal. Light burrs can be stoned smooth with emery cloth; deep damage requires shaft repair or replacement.

6. Remove the old seal
- Use a seal puller or hooked pick to engage seal lip edge and pry seal out evenly. Work around the circumference to avoid distorting housing.
- If seal lip is recessed, remove drive flange/retaining plate to access it.
- Avoid gouging the housing bore; protect the bore with a sleeve if using pry tools.

7. Clean and inspect
- Clean the bore thoroughly with solvent and rags. Remove old sealant/gasket material.
- Inspect seal bore and shaft for wear. If bore is scored, a bore sleeve or housing replacement may be needed. If shaft is grooved where lip seats, that will quickly eat new seals — shaft repair or replacement required.
- Replace bearings or races if significant wear or metal contamination was present in drained oil.

8. Prepare new seal for installation
- Verify new seal orientation: sealing lip faces the lubricant (generally inward toward gearbox fluid). The spring‑loaded lip typically faces the pressurized side.
- Lightly coat the inner lip and shaft with clean gearbox oil or assembly grease. Do NOT use heavy grease or sealant on the lip — only a light film.

9. Install the new seal
- Center seal on bore; use a correct-size seal driver or flat bar of same diameter. If a driver set isn’t available, use a short length of pipe whose outer diameter matches the seal’s outer metal case.
- Seat seal squarely by tapping evenly around driver face with a soft hammer. Bring seal flush with housing bore/mating surface. Do not cock the seal.
- If using an arbor press, press seal in slowly and evenly until fully seated.
- Avoid driving on the seal lip/body — impact to the lip will damage it.

10. Reassemble shaft components
- Reinstall any snap rings, spacers, bearings, flanges, and drive components in reverse order. Use thread locker or new lock washers where required.
- Torque bolts to OEM specs (consult workshop manual for correct values). If you don’t have the manual, document the parts and stop — do not guess torque values.

11. Refit gearbox to machine (if removed)
- Lift and align gearbox carefully; use alignment marks saved earlier.
- Reconnect hydraulic lines and sensors, ensuring fittings are clean and torqued correctly. Replace O‑rings on hydraulic fittings if disturbed.

12. Refill with oil
- Clean fill port area. Fill gearbox with correct oil type and quantity per OEM spec. Use a clean funnel and filter if required.
- Replace drain and fill plugs with new gaskets if required.

13. Test and check for leaks
- Reconnect battery, start engine, run at idle and cycle drive in low speed. Check for oil leaks around new seal and other disturbed connections.
- Operate loader under light load; recheck oil level and top up if needed after warm‑up and recheck torque on fasteners if required.
- Monitor for abnormal noises, vibration or oil loss during initial hours of operation.

Common pitfalls & how to avoid them
- Installing seal backward: confirm lip faces lubricant; incorrect orientation causes immediate leak.
- Damaging seal lip during installation: always use a driver that contacts the seal outer case and press/tap evenly.
- Reusing damaged/dirty components: always clean mating surfaces and replace O‑rings/gaskets. Contaminated oil or dirty housings shorten seal life.
- Not addressing shaft/bore damage: installing new seal on a grooved shaft or scored bore will fail quickly — repair or replace as needed.
- Incorrect torque: under/over torquing flanges or cover bolts can warp housings and cause misalignment or leaks. Use OEM torque specs.
- Not depressurizing hydraulics: can cause injury or oil spray — follow manufacturer depressurization procedure.
- Wrong seal or oil: always use OEM or exact-spec replacements (material compound, size). Some seals require different elastomers for hydraulic oil/temperature.

When replacement of other parts is required
- Replace seals, O‑rings, gaskets and sometimes snap rings as a matter of course.
- If drained oil shows metal flakes or bearings are noisy/sloppy, replace bearings, races, and any worn gears.
- If shaft is scored/grooved, consider shaft replacement or turning if within tolerances.
- Replace fasteners that show stretch or damaged heads.

Final notes
- This is a general, workshop-level procedure tailored to final-drive/gearbox output seals used on skid-steer loaders. Always reference the Toyota SGK6/SDK6/SDK8 workshop manual for exact part numbers, torque values, hydraulic depressurizing procedures, removal sequences and oil specifications for your model. If you cannot access the manual, stop and acquire OEM specs before final assembly to avoid damage.
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Toyota Huski 5SDK8 Skidsteer Toyota Huski 5SDK8 Skidsteer For more information contact equipment@g-es.net or visit www.g-es.net.

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