keeps getting worse

[wjm]

what started as a oil seal change
has grown into a rear brake flange needing replaced
and now theres approx a 16th of an inch of play in the pinion drive
should I bite the bullet and replace the whole FD

 

[juddadredd]

No, I wouldn't unless your planning a trip or are currently doing a trip, a 16th isn't too much but other people will have other opinions but at the end of the day it's your ride, if your've been riding it as it is and haven't met any problems apart from a leaky seal then if you hadn't of noticed your'd still be happily riding around wouldn't you.

 

[Bendy toy]

With the flange being cracked, the first call is to BMW they have been known to change these on high mileage bikes well out of warranty.

As for the bearing wobble... If I was changining the seal, I would go the extra step and change the bearing and check the state of the internal bearings. Ive read the stories about blown bearings so with it opened up would take the chance to confirm mine are ok.

To clean the seal try some old 35mm photo negative to clean out under the seal lip. It might be trapped dirt causing the leak.

 

[birdseye]

in which direction is your play - forward backwards or sideways? I dont believe there is a BMW tolerance for forwards / backwards but for sideways it is 0.3mm at the rim which is 12 thou. 1/16 is 60 thou.

whats wrong with the flange?

replacing the full unit is main dealer approach - its easier for them and risk free. if you want to be more thrifty then there is a lot of repair work that can be done to metal components by local specialists and which will bring things back to new quality at a more sensible cost.