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Seals, Gaskets, fittings & Hoses
FUNDAMENTAL SHOP SKILLS
HDER 1010
Heavy Duty/Truck &Transport Repair
Prepared by:
Wayne MacPherson
NSCC
Reference:
Martin W. Stockel
Martin T. Stockel
Chris Johanson
Auto Diagnosis, Service, and Repair
ISBN1-56637-910-5

Objectives
• Describe gasket construction & installation

• Describe seal construction & installation

• Describe sealant types & selection

• Describe fitting types & uses

• Describe hose types , construction & uses

Gaskets and seals
Seals, Gaskets, Fittings and Hose
Gaskets and Seals
Head Gaskets
1.Head gaskets are usually marked for the left and right banks on V
style engines.
2. Many head gaskets have the word top, front, or up stamped on them
to assist in
installation (figure 1).
Fig . 1 Head gaskets
Seals, Gaskets, Fittings and Hose

Paper and Cork Gaskets

1.Paper and cork gaskets that have been stored for some time tend to
either lose or
 pick up moisture, depending on storage conditions.

2. Loss of moisture can cause gaskets to shrink.

3. Excess moisture can cause them to expand.

4. In either case, they will show signs of misalignment.

5. This condition can be corrected by soaking shrunken gaskets in

water for a few

minutes or by placing expanded gaskets in a warm (150°F-200°F or
66°C-93°C)
spot.
6. Check them occasionally to prevent overdoing the treatment.
Seals, Gaskets, Fittings and Hose
Storing and Handling Gaskets
1.Gaskets should be stored flat, in their containers, and in an area
where they will

not be bent or crushed.

2. Storage space should not be subjected to extremes of temperature or

humidity.

3. Handle gaskets carefully, and do not attempt to force them to fit.

4. If a gasket is accidentally cracked or torn, throw it away.

Figure.2 Gasket damage.
A. Normal multiple-layer head gasket.
B. Gasket has been creased and the center
packing pulled apart.
C. Gasket straightened, producing a void.
D. Gasket has “ blown” in service.
Fig . 2 Damaged gaskets
Seals, Gaskets, Fittings and Hose
Making a Gaskets
1.If necessary, a simple paper or combination cork and rubber gasket
can be made,

(Figure 1).

2. First, trace the pattern.

3. Then, trim the material with scissors or lay the mate-rial on the part

4. Gently tap along the edges with a brass hammer to cut the gasket

material.

5. Screw holes can also be tapped lightly with the peen end of the ball

peen hammer.

6. Do not tap hard enough to damage the threads.

7. Gasket punches can also be used to make neat screw holes.

8. To help hold the material in place, tap out the corner holes and start

these screws
before tapping around the edges.
Seals, Gaskets, Fittings and Hose
Making a Gaskets
Fig . 3 Making a gasket
Seals, Gaskets, Fittings and Hose
Holding the Gaskets During Assembly
1.When a sealant is used, the gasket will usually stay in place during
assembly.
2. If sealant is not being used and the gasket tends to slip, use a thin
coat of grease or
quick-drying contact adhesive to hold the gasket in place.
Caution:The use of grease or sealant is not recommended on rubber
gaskets.
Seals, Gaskets, Fittings and Hose

Tightening Gaskets
1. Over-tightening will cause gasket damage.
A.Proper fastener tension.

B. Excessive tightening has split this pan gasket.

C. Excessive tension has warped this oil pan flange.

.
Fig . 4 Damaged to gasket caused by over-tightening.
Seals, Gaskets, Fittings and Hose
Steps to be Followed when Installing Gaskets
1.Clean parts, fasteners, and threaded holes.
2. Remove any burrs, bent edges, or excessive warpage, and check for
dents and
scratches (figure .5).
Fig . 5 Repairing damage to valve cover gasket mounting surface.
Seals, Gaskets, Fittings and Hose
Steps to be Followed when Installing Gaskets

3.Select a new gasket of the correct size and type.

4. Check the gasket for fit.

5. Where sealant is used, apply a thin coat of the correct sealant on

one side of the

gasket. Place the gasket with the coated side against the part. Spread
a thin coat
on the uncoated side.
6. If you anticipate difficulty in aligning the gasket during assembly,
secure the gasket

by additional means.

7. Carefully place the mating part in place.

8. Install the fasteners in their proper location and tighten them until

they are snug.

9. Torque the fasteners in proper sequence.

10. If necessary, retorque the fasteners after a specified length of

time.
Seals, Gaskets, Fittings and Hose
Oil Seals
1.An oil seal can be used to confine fluids, prevent the entry of foreign
materials,
and keep two different fluids separate.
2. An oil seal is secured to one part, while the sealing lip allows the
other part to
rotate or reciprocate (move).
 3. Oil seals are used throughout the mechanical parts of a vehicle.
4. The engine, transmission, driveline, differential, wheels, steering,
brakes, and
accessories all use seals in their construction.
5. Seals are made up of three basic parts:
a metal container or case; a sealing element;
and (on most seals) a small spiral spring
called a garter spring (figure 6).
Fig . 6 Oil seals.
Seals, Gaskets, Fittings and Hose
Oil Seals

6.Sealing elements are usually made of synthetic rubber or leather.

7. Synthetic rubber seals are replacing leather in most applications.

8. The rubber seal can be made to close tolerances. It can also be

given special

shapes and heat-resistant properties.

9. In the rubber oil seal, the sealing element is bonded to the case.

10. The element rubs against the shaft.

11. The case holds the element in place and in alignment.

12. The garter spring forces the seal lip to conform to minor shaft

runout (wobble) and

maintains constant and controlled pressure on the lip see (figure 7) .
Seals, Gaskets, Fittings and Hose
Oil Seal Construction
Fig . 7 Typical oil seal construction.
Seals, Gaskets, Fittings and Hose
Oil Seal Designs

1.Many different element and lip shapes are available.

2. Each is designed to provide the best seal for a specific task.

3. (Figure 8) shows several designs. Notice that more than one lip can

be used.

4. The outside diameter (0D) may be coated with rubber to provide

better (0D)
sealing.

A. Single lip .

B. Double lip with rubber shoulder seal.

C. Double lip style, both lips control oil.

D. Double lip with outer coat to assist

outside diameter sealing
Fig . 8 Typical oil seal design.
Seals, Gaskets, Fittings and Hose
Other Types of Oil and Grease Seals
1.Engine rear main bearing oil seals are available in both one and two-
piece styles,
(Figure 9).
2. They may be made of graphite-impregnated fiber wicking or
synthetic rubber.
3. Some grease (not oil) seals use a felt sealing element.

A. Main bearing ( rear) seal.

B. Typical grease seal.

C. Synthetic rubber main bearing

oil seal.
Fig . 9 Other seal types.
Seals, Gaskets, Fittings and Hose
Oil Seal Removal

1.Seals may be removed by prying, driving, or pulling, depending on

their location.
2. Use care to avoid damage to the seal housing during seal removal.

3. Such damage can cause leaks and make installation difficult. See

(Figure 10).

4. Before seal removal, notice the depth to

which the seal was installed.
5. As with a gasket, inspect the seal after removal
for signs of unusual wear or hardening.
A. Slide hammer puller, as puller is operated
the seal will be pulled out.
B. Using a seal driver.
C. Using a pinch bar (small pry bar).
Fig . 10 Seal removal methods.
Seals, Gaskets, Fittings and Hose
Seal Installation
1.After removing the old seal, carefully clean the seal recess
(counterbore).
2. Inspect the seal for nicks or burrs. Compare the old seal with the
new one to make
certain you have the proper replacement.
3. Place the seal against the opening with the seal lip facing inward, or
toward the
area in which the fluid is being confined. If the lip faces the other way,
the seal will
most likely leak, (Figure 11).
A. Seal has been installed backwards.
B. Seal has been correctly installed.
Fig . 11 Seal installation.
Seals, Gaskets, Fittings and Hose
 Seal Installation
4.The outside diameter must be the same. The inside diameter may be
slightly smaller in the new seal, as it has not been spread and worn.
The width can be somewhat different.
5. Seals are often damaged through improper installation. The technician
should be careful to use the correct seal driver or, if a driver is not
available, treat the seal with care.
6. The seal driver should be just a little smaller (about 0.020" or 0.51
mm) than the
seal outside diameter when the seal will be driven below the surface.
7. If the seal is to be driven flush (even with surface), the driver can be
somewhat
wider.
Seals, Gaskets, Fittings and Hose
 Seal Installation
8.In any case, the driver should contact the seal near the outer edge only.
Never
strike the inner portion of a seal. This might bend the flange inward
and distort the
sealing element, (Figure 12).
A. Punch struck the seal
case at point (A).
9. If a seal driver is not available, a short length of pipe of the correct
diameter can
be used. Make sure the ends of the pipe are cut square.
10. If a hammer is used to start a seal, follow it up with a drift punch. Be
careful to
strike the seal at different spots (near the outer edge) each time. If the
seal begins
to tip, strike the high side.
Fig . 11 Seal damage due to improper installation.
Seals, Gaskets, Fittings and Hose
Seal Installation
1. When installing a seal onto a shaft ,wipe the shaft clean and apply a
film of oil
or light grease onto the seal lip and inner face.
Fig .12 Installing a seal over a plain
shaft.
Fig .13 Installing a seal over a
splined shaft with the aid of a sleeve.
.
Seals, Gaskets, Fittings and Hose

Steps in Seal Installation

1.Clean seal counterbore, remove nicks and burrs, and if necessary,
coat with a very
thin layer of non hardening sealer.
2. Inspect the shaft and polish out burrs and scratches with crocus
cloth. Pay

particular attention to the area where the seal lip will be located.

3. Check the new seal for correct size and type.

4. Lubricate the sealing element and shaft.

5. If needed, install the mounting tool on the shaft.

6. Push the seal, lip edge toward fluid, up to the counterbore.

7. Using a suitable driver, seat the seal. Make certain it is inserted to

the proper
depth and is square with the bore.
Seals, Gaskets, Fittings and Bearings
 O-Ring Seal Construction
1.O-ring seals are generally solid, doughnut-shaped, and made from an
elastic
substance (synthetic rubber or plastic).
2. They are used to create a seal between two parts, close off
passageways, prevent
the loss or transfer of fluids, and help retard the entry of dust and
 water. See
(Figure 14).
A. Note how the
O-ring is fitted
into the Groove
in the shaft.
B. Typical O-ring
construction.
Fig .14 O-rings
Seals, Gaskets, Fittings and Hose
O-Ring Operation
1.Because the O-ring is composed of a soft, pliable material, it seals
when slightly
squeezed between two surfaces.
2. If the O-ring is also sealing under pressure, the pressure itself will
aid in deforming
the ring, further making a final seal.
3. O-rings can be used to seal both static (nonmoving) and dynamic
(moving) parts,
(Figure 15).
A. Static seal.
B. Dynamic seal.
Fig .15 O-ring operation.
Seals, Gaskets, Fittings and Hose
O-Ring Installation Steps
1.Make sure the new O-ring is the correct size and that it is compatible
with the fluid

being sealed.

2. Thoroughly clean the area where the O-ring is to be installed.

3. Inspect the O-ring grooves or notches for burrs or nicks that could

damage the
new ring. Dress any sharp areas with a fine abrasive stone. Thoroughly
clean the
area to remove any metal and stone particles.
4. Check the shaft or spool (if used) for sharp edges or nicks. Remove
any damaged
spots with a fine abrasive stone or cloth. Clean the area thoroughly.
5. Before installation, lubricate the O-ring with the same type of fluid
used in the part
or system.
6. Install the O-ring. Protect it from sharp edges and other parts. Do
not stretch it
more than necessary.
•
Seals, Gaskets, Fittings and Hose
O-Ring Installation Steps
7. Be sure the parts are correctly aligned before mating to avoid
damage to the
O-ring.
8.Make a final check after the O-ring is installed to be sure there are
no leaks and
that the parts move correctly.
•
Seals, Gaskets, Fittings and Hose

O-Ring Failure Diagnosis

1.Improper handling, installation, and application will reduce O-ring
service life.
2. (Figure 16) illustrates some common
O-ring failures and their causes.
3. When replacing O-rings that have failed in
service, try to determine the reason behind
the failure.
•
Fig .15 Typical causes of O-ring failures.
Seals, Gaskets, Fittings and Hose
Sealants
1.Sealants, or gasket sealers, are liquid or semi-liquid materials that
may be sprayed,

brushed, or spread on the gasket surface.

2. Various types, having different properties, are available.

3. Some set up hard, and others are nonhardening (remain pliable).

4. Some can be used in place of a gasket, since they are able to form

the gasket when

placed between two mating surfaces and allowed to dry.
Seals, Gaskets, Fittings and Hose
Form-in-Place Gaskets
1.Form-in-place gaskets are sealers that can be used in place of
conventional

gaskets.

2. They can be very useful when an exact replacement gasket is not

 available.

3. Some general rules for using form-in-place gaskets are:

A. The gasket surface should be clean. Use a wire brush on all gasket
surfaces to
remove loose material. All oil and dirt should be removed, and blind
holes
should be inspected to ensure that they are free of old gasket
material.
B. Inspect all stamped metal parts to ensure the gasket mounting
surfaces are
flat. Straighten if necessary.
C. Apply the gasket material in a continuous bead of approximately 1/10"
(3mm). The size of the bead should be even over the entire sealing
surface.
Too thin a bead will fail to seal properly, while too much sealer may
clog a
fluid passage.
Seals, Gaskets, Fittings and Hose
 Form-in-Place Gaskets
D.Circle all bolt holes with a bead of sealant.
E. Do not allow the material to dry before installation. For best results,
the parts
should be assembled within 10 minutes and torqued in place within 15
minutes.
F. Remove all excess material with a rag before it dries.
G. A technician should be thoroughly familiar with sealants and their
properties.
The chart in (Figure 16) lists various sealants, their properties, and
recommended uses.
Seals, Gaskets, Fittings and Hose

Review Questions ( Seals & Gaskets)

1. Some parts, such as __ , should be checked for dents where they
meet the gasket
and straightened if necessary.
(A) valve covers
(B) cylinder heads
(C) engine blocks
(D) intake manifolds
2. Why should the technician try to determine the reason for gasket
failure?
3. Which of the following is not part of a typical oil seal?
(A) Outer casing.
(B) Sealing element.
(C) Locking fingers.
(D) Garter spring.
4. When removing an oil seal, it is important not to damage the __ .
(A) sea/lip
(B) seal housing
(C) seal case
(D) garter spring
Seals, Gaskets, Fittings and Hose
Review Questions ( Seals & Gaskets)
5. What should be placed on the lip of a seal before installation?
(A) Nonhardening sealer.
(B) Hardening sealer.
(C) Lubricant.
(D) None of the above.
6. O-rings are usually made of __ .
(A) copper
(B) rubber
(C) treated paper
(D) cork
7. Nonhardening sealers remain __ .
(A) flexible
(B) liquid
(C) brittle
(D) None of the above.
8. Some sealants are used to make.
(A) seals
(B) gaskets
(C) O-rings
Seals, Gaskets, Fittings and Hose
Fittings and Tubing
Fittings)
Seals, Gaskets, Fittings and Hose
Tubing, Fittings and Connectors (Flare Fitting)
1.In a flare fitting, the end of the tubing is spread (flared) outward at
an angle. The
tube nut securely grasps both sides of the flare to produce a leakproof
joint,
(Figure 16).
2. The flare fitting can be of the SAE (Society of Automotive Engineers)
type, or the
inverted type. Tube nuts for flare (and compression) fittings are
available in both
standard and long lengths.
3. Where the installation is subject to heavy vibration, use the long
nut.
Fig .16 A typical flare fitting SAE 45 degree.
Seals, Gaskets, Fittings and Hose
Flare Fittings
4. There are two flare angles, 37 and 45 degrees. Be certain to
determine the one
needed before starting.
5.The flare may be of the single-lap, double-lap, orISO (International
Standards
Organization) type (Figures 17, 18 and 19).
Fig .17 Flares (A) is 37 degree (B) is 45 degree.
Fig .18 Flares (A) is single (B) is double .
Fig .19 ISO or ( bobble flare).
Seals, Gaskets, Fittings and Hose

Forming the Flare

Caution: When flaring double -wrapped brazed steel tubing always use
a double-
 lap flare or an ISO flare. If a single lap is used with this type of tubing
It
will split.
1.Flare fittings can be used on any type of tubing (copper, aluminum,
steel) that will
lend itself to flaring.
2. Flared connec-tionsm ust be used in high-pressure automotive
applications, such

as brake and power steering systems.

3. Flare the tubing, making certain the flare is of the correct angle and

width.

4. The flare must be smooth and square

with the centerline of the tubing.
5. Careless cutting or improper use of
the flaring tool will produce weak
and uneven flares, which may leak
(Figure 20).
Fig . 20 Correct & incorrect flares
Seals, Gaskets, Fittings and Hose
Forming a Double-Lap Flare
1. A double-lap flare should be used on brazed steel tubing, thin-wall
tubing, and all
tubing that will be subjected to high pressure.
2. After cutting, reaming, and determining the proper flare angle, slide
a fitting nut
onto the tubing and insert the tubing in a flaring tool.
 Note: Always follow the instructions provided by the tool's
manufacturer.
3. The flaring tool shown in (Figure 21)
will produce either a single or
double-lap flare.
Fig . 21 Flaring tool.
Seals, Gaskets, Fittings and Hose
Forming a Double-Lap Flare
4. To use the tool, arrange the grip-ping blocks so the correct-size
tubing hole is

directly beneath the flaring cone.

5. Rotate the adapter plate until the correct size adapter is beneath
 the cone.

6. Push the tubing through the gripper blocks until it strikes the

adapter.

7. Tighten the block securely so the tubing

cannot be forced downward under
flaring pressure.
8. Run the flaring cone down until it forces
the adapter against the gripping block
and bells the end of the tubing,
(Figure 22).
Fig . 22 First step for a double flare.
Seals, Gaskets, Fittings and Hose
Forming a Double-Lap Flare

9. This is the first step in doing a double-lap flare.

10. Next, turn the flaring cone back.

11. Swing the adapter out of the way, and run the cone tightly down

into the belled

tubing, ( Figure 23).
12. This will form the finished flare.
Fig . 23 Second step for a double flare.
Seals, Gaskets, Fittings and Hose

09 Seal, Gaskets, Fitting and Hoses

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