Axle Seal Keeps Leaking

[SVT_CT]

After replacing the driver side axle (99 CSVT) the MTX fluid leaked out of the axle seal. I replaced the axle seal and re-installed the axle, this time using a hammer and block of wood to hit the axle in and make sure it connected properly. It leaks again.

The C-Clip seems a bit loose on the end of the axle. i dont remember if it came like this or was loosened from installing it twice or during removal (it came new with the axle). I can supply a pic if needed.

Is there anything I am missing here or anything else that I should check? Any other ideas?

 

[SVT_CT]

I think I will check the diameter of the replacement axle against the original (where the axle meets the seal). Any other ideas would be appreciated.

 

[andreslobo]

Usually you need an act of congress to get the drivers side axel out. If it popped out easily, I would say that the $10 clip on the trans end of the axel is shot, if that is the case it would allow the axel to come out far enough to leak oil.

 

[SVT_CT]

The axle seemed to be tight but not super difficult. Using a pry bar against some wood on the transaxle took some force to pop it out, but i would not say excessive force. In my opinion my clip seemed a bit large even before I installed the axle.

More about the clip: From the beginning the new axle's clip seemed to be hanging too loosely on the end of the axle, as if it wasn't compressed enough during manufacture. I know the clip isn't supposed to grab the axle tightly, but my clip seems to be extra loose. I attached two pics.

Is my clip too loose?

 

[crewchiefpro]

Can you pull the axle out now? If it does not seat all the way in it will leak. How about a picture of the axle inside the trans so we can comment on how far out it sits.

 

[SVT_CT]

I'm not at home now but when I tried to pull on the axle by hand Saturday it seemed connected well. It didn't seem like I could pull it out without using the prybar/wood. I will get a pic later or tomorrow (still at work and it has been raining like crazy here). I know a picture is better, but FWIW during the second install attempt I did visually compare how far the axle was sitting against the pass side axle and they seemed to be sitting the same (although I dont even know whether the pass and driver side axles are supposed to sit the same distance out or not).

Also, after my first install attempt I did some searching here and found out I could pound the axle pretty hard during install (with hammer + block of wood on end). I tried pounding it in during the second install (after replacing the seal) so maybe my clip is bad.

 

[andreslobo]

It isn't the clip. From your photo the clip looks fine. It is supposed to expand outwards into a groove in the differential, so loose is good.

You didn't punch a hole in the case prying out the old axel did you? Look carefully.

Before you replace the seal this time make certain that the sealing surface on the axle is smooth and make certain you apply some sealant to the outside of the seal, make certain that the seal surface in the trans is not buggered. Best of luck

 

[SVT_CT]

What type of sealant should I use?

 

[BrApple]

anerobic

 

[striker2]

there shouldnt be any sealant on the axle seals.

 

[SVT_CT]

Per crewchiefpro's request I attached three pics of the axle as it now installed to show how it is seated (in this state adding MTX fluid makes it leak).

Also, earlier I stated that the original axle was hard to remove but not too hard....well I started removing the axle again (after the attached pics were taken) and this time it is hard as hell to remove.

Other than checking the diameter of the axle where it meets the seal (to see if it is too small thus causing the leak) I am at a loss as to what to do next. Any other ideas?

 

[striker2]

is it a reman axle or brand new?

from those pictures it looks like its seated all the way, might be able to go in a touch farther but i dont think so.

 

[SVT_CT]

It's a brand new axle from Advance Auto. I believe the brand is GCK or something like that.

 

[aircougar]

When you installed the new seal, did you maybe pop out the spring that sits inside the seal by accident?

If you tap the seal really hard, that spring can pop out of the seal... the spring puts a slight amount of tension on the inner rubber piece that touches the axle, and prevents it from leaking. I have had the spring pop out on a timing cover seal and didnt even know it, and it was leaking because of it.

 

[SVT_CT]

Aircougar...thanks for the tip, I know the spring you are talking about. My next step was to check the diameter of the new axle vs the original, but I will check for that spring first when I pull the axle again.

I am having a lot more trouble removing the axle than the first time so I rented an axle puller set from Advance. Unfortunatley it only pulls at the outer end of the axle which just causes the inner joint to come apart! I am ordering a Ford axle puller shaped like a "C" which hooks behind the inner joint (used with a slide hammer) and will update when I get the axle out.

 

[striker2]

you can rent the CV puller from autozone.

 

[SVT_CT]

Thanks, that saves me a few days of waiting..... I had checked NAPA, Pep, and Advance before giving up on renting one.

 

[striker2]

i posted just recently what the part number for it from them is as well. since some of them seem to have a hard time finding it in their system i usually go in armed with the PN and tell it to them as well.

 

[SVT_CT]

UPDATE:
Removed axle with slide hammer and rented axle puller adaptor (Autozone part #27058). I can't see or feel if the spring is there (or not) so I will buy a "dental" inspection today mirror and check for the spring tonight.

Also, checked diameter of new vs old axle where it meets the seal. The new one is actually a slight bit bigger so the leak isnt being caused by smaller axle diameter.

Lastly, I noticed an extra groove on the splined end of the old axle that is not present on the new axle (pics attached). Was I given the wrong axle? Could the absence of this groove cause the leak?

 

[SVT_CT]

I checked and the seal spring is present, unfortunately. Does anyone know about the extra groove on the original axle? (see previous post pics). Did I get the right axle?

Right now I'm thinking of just replacing the seal again (I bought two) and trying again with a different new axle.