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: