Doing a job correctly is evidently not enough. In my 18 years as a Mechanic I never had the below problem happen.
I also do not know how to prevent it from happening again!

Apparently when I drove the new Seal into the Differential the Seal Lip Spring popped out.

I did not see it until I was about to install the Differential.

I tried all kind of ways to try to get the Spring back onto the Lip and ended up damaging the Spring.
The Spring in the picture is on from the Old Seal I removed. Removing the Seals destroys the Seal.

After having welded up my Cracked Rear Cross Member I had just enough time this Weekend to get my Car back on the Road.
To add to that yesterday I cracked a piece off of one of my Front Teeth. I had to stop working on the Car get cleaned up and went to the Dentist only to find they were closed. More time wasted!

So it is clear I cannot finish the Car this Weekend.

Monday I start Jury Duty; so cannot plan on being able to fix the Car during the work Week.

I a curious to see if this has happened to anyone else and how they got the Spring back on.

Attached Thumbnails

 

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84 300D, 82 Volvo 244Gl Diesel