Hi, the seal has been installed with a hammer, they have hit it around the
 edge and this is what has "torn" the edge of the seal. You will note the
 edge of a steel casing under the torn rubber, if you hit the seal with a
 hammer to install the splitting is the end result.
 Use the proper install tool to fit the new seal OR use a block of wood
 between the seal and the hammer.
 John.

> ----- Original Message -----
> From: "David Shepherdson" <shepherdsond@METRO.DST.OR.US>
> To: <vanagon@GERRY.VANAGON.COM>
> Sent: Thursday, October 20, 2005 4:24 AM
> Subject: Re: Failed Crankshaft seal - 2nd time!
>
>
>> Thanks for the feedback I received on this.
>> I removed the engine and flywheel and found that the seal is indeed
>> split, for photos go to:
>> http://www.solisearch.net/ims/album.php?u_id=271241B2Q0
>>
>> Last time this happened the seal was sticking out and rubbing on the
>> flywheel according to the mechanic that replaced it (3k miles ago).
>> However, this time it is not sticking out beyond the edge of the casing.
>> Bob Donalds and Al informed me that there are at least 2 and possibly
>> three different seals under the same part number.  I checked with 2
>> FLAPS in my area and sure enough one was selling a seal that was 12mm
>> deep and the other 10mm deep (according to the specs - I have not
>> actualy measured them).  Bob says that the thicker seals can rub on the
>> flywheel.  My failed seal is 12mm deep but it does not stick beyond the
>> casing edge (it is recessed by about 1 mm in most places) so I wonder if
>> this could be the problem.  I have not checked end play yet but will try
>> to this week - could this realy be the problem though since the seal
>> does not stick out and the lips look fine? Does anyone have any further
>> ideas, does this look like the result of a faulty istall?? I guess I
>> will just have to put in a 10mm seal and hope for the best.  I dont like
>> the thought of being deep in the backcountry and having this happen
>> again!
>>
>>
>>>>>>>>>>>>>>>
>>>>> David Shepherdson 10/14/05 9:43 AM >>>
>> As if I did not have enough problems with my 87 syncro, I was on the
>> way to the airport yesterday when the crankshaft seal failed and
>> dumped most of the oil on the road (I missed the flight!).  I
>> couldnt believe it because the same thing happened about 3 months
>> (and 3000miles) ago on my way up to Northern Canada.  That time I
>> was able to get it towed to Kamloops and have it repaired while I
>> continued my trip at considerable expense in a rental.  The guy that
>> repaired it said that the seal had been sticking out too far and had
>> finaly torn (I have the seal and a chunk is missing)probably from
>> rubbing on the flywheel.  He thought that it probably had not been
>> installed properly (it had been dripping ever since I purchased it 4
>> months previously)in the first place (the engine is a rebuild with
>> about 25k miles).  However, now that it has happened again so soon I
>> am left wondering what could possibly cause this.   I have talked to
>> others that have said that in other cars this can be symptom of a
>> warped engine casing.  I cant afford to have my mechanic fix it this
>> time so I need to know what to look for.  Can anyone give me any
>> ideas about what could be wrong and how I can fix it?
>> Thanks for this help and other help that I have received from this
>> list.
>> David
>