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Old 12-29-2019, 01:35 AM
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Join Date: Mar 2007
Location: Seattle, WA
Posts: 300
e39_touring is on a distinguished road
Replaced rear main seal on 3.0 and have a leak

I've mentioned in other threads that I was doing a ton of work to my X5 (3.64 differentials, single-mass flywheel conversion, trans detents, oil pan gasket, etc.). Well, I thought I was done, but now it looks like I have to go back in for a botched rear main seal replacement that I did 'while I was in there'.

I just bought the seal only (corteco) and not the whole kit with the carrier and bolts, etc. I carefully tapped the new seal in flush with the face of the carrier, just like the original. I used a new seal (the metal one) that goes behind the carrier, oiled the seal and crankshaft, and used the plastic 'installation tool' to guide the seal while sliding it on. I cleaned the threads (male & female) on those two lower bolts that go into the oil sump and used blue loctite on them to seal the threads.

I thought I did a good job, but I've got a pretty good drip now. I blotted the oil droplets and didn't get any more forming while the vehicle sat for about 2 hours. Then I drove the vehicle out of the garage and then back in, and I had oil drops forming (sort of from the big bellhousing bolt on the right on down to the long vertical oil pan bolt in the pic).

Does this indicate it's not the oil pan gasket or that lower bolt that goes into the sump? If it's only leaking while the engine's running, that would be the main seal, right? Any chance it will 'wear in'? (the crank surface had noticeable worn grooves in it where the old seal rode).

pretty bummed right now at the prospect of pulling the tranny, clutch & flywheel again...
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