Water Pump seal and Oil seal on 2003 Sportsman

SO there are some good threads on this topic here. I have read alot that say they have replaced both the mechanical water pump seal and the oil seal located right beside it BOTH from the water pump side. There are some who warn this is wrong and beware.

As I do not have the money to fork over to the dealer, I am going to try the water pump side to do both.

I have ordered them and will have parts in a couple days.

So far I have taken off my stator cover, water pump housing and plate, nut and washer holding on the impeller, the impeller itself, the water pump seal and the oil seal. On inspection, there was alot of crud on the back of the water seal. I do a fair bit of deep mudding, so I am thinking the dirt came in the weep hole and hurt my seal. Also, the washer that goes between the impeller and water seal (comes in the kit apparently) was melted/fused with my impeller. Thereis a pic of the water seal on its side. You can see the two small holes I drilled in so my screws from my puller could bite into it to pull it out.

The oil seal seemed fine, minus the two holes I put in it removing it. (see photo..oil seal is still in place on the shaft in the photo)

I removed both seals using a puller type method, screwing into them and GENTLY pulling them off with a few turns of the screws.(see photo. I am holding home made puller. The shaft in the background is clear of all seals, the photo was an afterthought to show the puller I made from a plate used in light fixtures)

There was never any pressure on the shaft and I was careful not to hit it at all.

I will post pics, and some other pics online are exactly the same as what I saw.

One word of advice. When you get the copper water seal off, I was faced with a solid blue surface. When I started to drill in my self tapping screws, I expected rubber, but it was a rubber seal with sturdy metal in it. I was worried I was boring into the metal surface of the gears or bearings, but I wasnt.

Also not mentioned in the other posts is a suggestion to jack up the right side of your machine to stop the oil form dripping out all over. I have been told to ensure the shaft and all surfaces be clean of grime and oil and to use rubbing alcohol to accomplish this.

I believe the thing that has made this successful so far is to not be in a rush and to be gentle, take your time.

I will be using a 24mm socket for the oil seal (see photo) to tap it gently into place evenly and slowly. I have taken pics of the exact depth it was sitting at before, so I know how deep to tap it in.

For the water seal, I have a metal cylinder the same diameter as the copper lip of the water seal. I will use it to tap in the seal to the proper depth. (mag light shaft)

If anyone has any installation tricks or advice, please let me know.

Ill post more photos soon.

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