Rear Main Seal Install on 1994 Chevrolet Suburban 5.7L w/ 4l60E trans

After a few months I am finally getting back to the trans swap on my Suburban. One of my younger kids had hip reconstruction surgery and her recovery was a long and complicated one. Anyway, to review, my transmission had gone out so I got another one to put in. The engine is fine but has a bunch of big oil leaks so I pulled engine and trans out together. Right now I am working on replacing the engine's rear main seal. Engine and trans are apart, flex plate off, oil pan out (incidentally I also went ahead and replaced the oil pump). Haynes Guide says it is supposedly possible to install new rear main seal without use of the expensive (I priced at $350.00) special seal install tool. I have tried, and for me at least, it ain't happening. I have already destroyed one new seal and had to go to auto parts store to get another.

Just need some ideas on how to get rear main seal installed without destroying it again and hopefully without having to buy a one-use $350.00 tool. Or are any of you guys local to the DC area who are willing to let me borrow tool? I'll put down a deposit, you'll get the tool back in same condition I assure you . . . Auto parts stores here do not have them in their loaner programs.

Any ideas appreciated!

~ Pop

Hey sir! Glad to hear your daughter is doing better. This is they type of seal it uses, correct?

www.rockauto.com/en/moreinfo.php?pk=256284&cc=1302332&jsn=2485

I've always had the best luck using pieces of exhaust pipe. 4.5" is a bit big for exhaust pipe, but it's out there. I find a piece that's close, then expand it as needed so it squares up with the outermost diameter on the seal. Then, beat it in with a rubber mallet 'till the seal is at the right depth.

It's unconventional, but it sure beats dropping $300 on that special tool. :lol: Perhaps a local exhaust shop could help you? Tell them what you're doing, the diameter you're going for, and that you don't care how pretty it is.

I have used random pieces of pipe and works fine for this but I did notice they sell generic tools for this under 100 if you can't come up with a pipe the right size.

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Thanks guys! I found some 4” PVC pipe lying around that appears to be the perfect diameter. Will try this first! I’ll let you know.

Ah yeah, that'll work!

I guess the other option would be to remove the rear main housing plate, drive the seal in on the bench, and install the plate with new gaskets.

This is how Haynes guides us to do it. I kept popping seal out.