Thread: passenbger side axle seal STILL LEAKING FFS!

Okay here are some pics:

1) here is the diff housing after removing the fourth seal (OEM seal and three leaking 3543 leaking seals):



2) Here are the two seals side-by-side. The green one is the one that doesn't leak. You can see the difference in depth below the flange. On the orange one, it puts the sealing surface on the axle shoulder which caused the leaking:







3) Here is the axle. You can see the transition from large OD to small OD is filleted. From a structural standpoiunt, this makes sens as it reduces stresses. But, from a functional standpoint, it meant that the orange seal would not seal as it was riding on the filleted shoulder. The OEM style seal had the black seal surface further up the shaft:



4) Here is the final installation. Fourth time was the charm - dry as a bone now:

I wondered that too.

I don't know.

I wish I had the OEM axle still as I would check its measurements.

What I can say is that the OEM style seal does not leak AT ALL with this axle.

The aftermarket seal is not out of spec with respect to diameter.

The OEM seal came with flyer in the baggy saying "this new seal replaces the original seal to prevent leaks. this new seal locates the seal 2mm further up the axle".

I tossed the flyer or I would post a pic. Clearly, there are two types of seals that will work for this application.

Also, I checked the axial length/diameter relationship with the seal. The filleted shoulder of the axle is FLUSH against the bushing - it can't be pushed in any further. So, the only reason that the new axle COULD differ from the OEM axle is the transition from smaller diameter to larger diameter. Ironically, the filleted design of the A/M axle is SUPERIOR. Moreover, I PRESUME the OEM axle didn't ALSO have this design.

Hindsight being 20/20, I would have mic'ed the OEM axle and confirmed if the shoulder is filleted like the new axle.

It's a 50-50 shot that the OEM axle would have ALSO leaked. Since I returned it for a core, I don't know what type of shoulder it has.

I'm not going to pull my CV to measure it, so really all I want is confirmation that the shoulder is or is not rounded OEM.

I just went through the same thing with different seals on the wifes car. Ended up buying one from the dealer and installing it today. Now it is not leaking.