Teflon Rear Main Seal -- Installation Difficulty

[Eulers]

Hi. Am still having difficulty installing a FelPro Teflon Rear Main Seal (#BS40644) into a stock 1987 5.0 (T5 tranny) despite having tried a number of the tips from the various StangNet threads.

Any further suggestions appreciated.

Below I describe my (1.) Difficulty and the (2.) Installation Tips Tried so far.

(1). DIFFICULTY:

(A). The FelPro directions specify to install the seal DRY (in capital bold letters on the instruction sheet). Unfortunately, "DRY" creates resistance so that the seal tends to spring back out from its groove when I'm attempting to tap it in.​

(B). The new Teflon Rear Main Seal seems to hang up on the outer circumference of the seal where it contacts the block.​

(C). Consequently, I cannot get the Rear Main Seal to slide EVENLY into its groove between the block & crank. There is always some portion of the Seal's perimeter (about 15 degrees worth) that pops back out. It's just like playing the Whack-A-Mole Gopher Bash Game. Typically, I get over half the depth of the Seal seated into its groove except for a 15 degree section that keeps springing back out at me.​

(C). My last effort: I finally forced that 15 degree section in with a 3/4" X 2" wood block & rubber mallet. However, upon doing so I heard the sound of plastic snapping or cracking. I imagine it was breakage of the Seal's outer teflon ring as it was forced under the face of the engine block. So, I'm going to remove and try a new Teflon Rear Main Seal again with any of your suggestions.​

(2). Installation Tips I've Tried:

(i). The FelPro Teflon Rear Main Seal comes with its own Seal Installer. I used it in all my attempts.​

(ii). Used the old Main Seal mounted on a thick polycarbonate sheet so I could hammer on the sheet and evenly pressure the new Seal to slide in evenly (theoretically). In reality it did not.​

(iii). Also tried just the old Seal alone on top of the new seal. (I would tap on the old seal with a rubber mallet).​

(iv). Also tried just tapping on the new seal in a star pattern with a 3/4" x 2" wood block and rubber mallet.​

(v). Also tried chilling the new seal b/c it seems to hang up on the outer circumference of the seal when it contacts the block.
​

A bit long-winded but thanks for bearing with me. Any ideas?

 

[Rick 91GT]

I usaully have no issues when using the seal installer, I do have a piece of delrin I made that same size as the seal to help push/tap them on. If you can find a piece of tubing or pipe the size of the seal it makes tapping it on much easier...

I always put a very light film of oil on the crank...

 

[cardudeusa]

I've done it multiple times using the installer they send with it. Never had a problem.

 

[89drop]

im thinking in the directions it means the seal should be dry, but maybe lightly lube up the block?

 

[Jaswir]

never had any problems installing them ive done about 3... just lighty tap it in even all the way around it should just slide right in..