Remove the half shaft.
Carefully mark the position of the seal nut/flange.
Remove the seal/nut flange while counting the number of turns (partial turns count as well). (RD Enterprises sells the tool. Do not use a hammer and screwdriver!)
Pry out out seal run sleeve.
Replace seal run sleeve o-ring (lubricate well and push hard. It will "pop" into place).
Replace seal and lube seal lip with light grease.
Clean threads. Coat with non-hardening sealant (Hylomar).
Reinstall seal/nut flange to EXACTLY the same position.
Refit fit half shaft and shim properly.
Shop manuals can be found here:
http://www.lotus-europa.com/manuals/index.htm
Adding to what JBC posted and just my personal opinion and experience from my last two seal replacements.
Remove the half shaft.
Carefully mark the position of the seal nut/flange.
Remove the seal/nut flange while counting the number of turns (partial turns count as well). (RD Enterprises sells the tool. Do not use a hammer and screwdriver!)
Heed the warning about not using a hammer and screwdriver. New finned nuts are almost unobtainable if you break off the fins, ask me how I know. One readily available and cheap effective tool is a motorcycle clutch basket holder. It works very well in removing tight tranny seal nuts. Pry out seal run sleeve.
I flipped the clutch basket holder tool 90 degrees and use it as a vise grip to clamp onto the sleeve to wiggle it out. The metal of the tool is softer than the sleeve so there is no chance of scratching the surface of the sleeve.
Make sure that the old shims stuck to the yoke or sleeve on the transaxle are removed. Use the number and thickness of the old shim as a starting point for you new shims. The final number and thickess of shims may be different when you get done.
Replace seal run sleeve o-ring (lubricate well and push hard. It will "pop" into place).
My "O" rings were extremely difficult to pop into place. What I did was to re-install the wheels and lowered the car to the floor. The weight of the car popped the sleeve over the "O" ring over time. Just make sure that the "O" ring and sleeve or well lubricated. That "O" ring is the second barrier to gear oil leaks. Any tears or nicks in the "O" ring and you will eventually end up with leaks.Replace seal and lube seal lip with light grease.
Clean threads. Coat with non-hardening sealant (Hylomar).
Sealing up the super fine threads of the retaining nut is the last step in reducing the chance of oil leaks from the output shafts. I've used both Hylomar and Loctite 580 pipe thread pipe sealant with equal success. All you need is a very tiny amount of sealant to coat the threads or you will end up cleaning up the squeezed out excess when you are done.
Reinstall seal/nut flange to EXACTLY the same position.
Refit fit half shaft and shim properly.
Shimming of the output shaft is the most labor intensive part of the job. There is a ton of postings on how to shim in the Knowledgebase. Read up on it before you start.
I found the pictures of the clutch basket holder tool.
http://www.lotuseuropa.org/LotusForum/index.php?topic=648.0Joji Tokumoto
Fallbrook, Ca
