10.1 - PAS top cover shaft seal fix,(Speedy-Sleeve) ( Craig Kercheval,  September 23, 2003 )

Unlike many of the initial postings, this one is not to pose a
problem, but to post a solution. It involves the installation of a repair
sleeve (called a "Speedy Sleeve) onto the top shaft of the power steering box.
Hopefully, this info will come in handy for some of you.

Several months ago, I noticed a fairly major leak from the Power
Assisted Steering box. I saw that fluid was not only leaking with the car
running, but even when the car was resting in my garage. The leak was
coming from the seal around the shaft which connects to the steering column.
This was puzzling, since I had recently replaced the seal - on two
separate occasions to try and stop the leak. Since I had followed Jaguar's
instructions carefully when disassembling the top cover of the box and since
I renewed not only the seal, but the two o'rings which are part of that
component, I was surprised (and dismayed) that the leak continued as it had
before I essentially rebuilt the top cover those two previous times.

During the course of my research to find a solution I got
several doses of good advice, not to mention moral support
from Chris Burdo, one of the listers here. Now that I have
finally found the right fix for this leak, Chris suggested that
I post my findings to this group. So, while the solution here is
unsolicited at this time, perhaps it will come in handy for anyone's
Jaguar sedan who experiences leaking from the same spot as on my
car.

I'll try to summarize here, based on the learning curve I just
went through.

Car:
1966 Jaguar 3.8S with 40,700 total miles.


Problem:
Leaky Power Assisted Steering box from the top shaft seal. This
is the shaft which connects to the steering column. After years of
trouble-free operation, fluid began leaking from the seal when the
car was running, and continued to leak when the car was not running.
Continued leaking approx. 1-2 oz. a day with the car sitting in the garage.

Solution:
Installed a "Speedy Sleeve" on the top shaft. Replaced the shaft
seal and the two o-rings in the top cover.

Reference:
Jaguar 3.4S and 3.8S Models Service Manual. See page I-38
section on "The Top Cover" plus illustrations.


Replacement Parts:
Speedy Sleeve - Part # 99076 made by Chicago Rawhide
Seal (double-lipped) - Part # 7443 made by Chicago Rawhide
O'ring - Size .028
O'ring - Size .042


Procedure Notes:
Rather than repeat text from the Jaguar Manual, I have only
commented based on my recent experience with this procedure.
(The assumption is that the box has been removed from the car
for this procedure)

Speedy Sleeve comes with clear instructions and a tool included
to drive the sleeve onto the shaft. Basically, installation involves driving
the sleeve onto the shaft to cover the area of the shaft which is directly
inside the top cover seal. On my car, I stopped driving the sleeve at a
point where about 1/4" of the shaft shows beyond the splines. Although the
Speedy Sleeve was the correct diameter for the shaft, the splined part of the
PAS shaft on my car needed to be sanded down in order to allow the sleeve to
go over the splines without binding. I used 400 grit paper on the splines,
checking until only slight resistance could be felt with the sleeve
slipped over the splined part of the shaft.


I removed everything from the top cover, per the Jaguar Manual
instructions, except the shaft seal, which I left in place for measuring
purposes. Before removing the old seal from the PAS top cover, measure the
distance along the shaft where the sleeve must be installed. The sleeve is only
about 1/2" long, so it is critical that it be driven directly under where
the seal will sit with the top cover in place.

Use a non-hardening sealant, like Permatex, which will act as a
lubricant, when spread thinly on the inside of the sleeve before driving it
along the shaft.

After gently driving the sleeve in place over the shaft, and a
final check of the top cover with the old seal in place, the old seal can be
removed from the top cover. The new seal can then be pressed, or lightly
drifted in place inside the top cover. I used a thin coat of Permatex
non-hardening sealant around the outside and front of the seal, careful not to
get any on the rubber seal. After the seal is in place, of course, it must
be lubricated with the same fluid used in the PAS.

With the new o-rings (lubricated with same fluid used in the
PAS) installed and all components back in place in the top cover,
the top cover can then be tightened down onto the steering box.