Axle seal leak driving me mad

[hour]

I finally got around to replacing my 7 year old CVJ axles recently, whose boots failed last winter and were probably gunked up pretty bad from water and dirt and stuff.

I originally tried to use Duralast axles for this job, knowing well that they sucked (4runner is for taking dogs around town anymore - IDC) and was proven correct - they suck. I installed the passenger side but realized the threading opposite end was chewed up, so it had to come back out. Didn't even bother doing the drivers side, because the second duralast axle also had chewed up threads :wacko:

Removing the just-installed passenger side involved some prying and in the process I damaged the axle seal, which I had installed new (OEM) when I did the CVJs 7 years ago. Big deal, ordered a new one from the dealer (part # verified by them, the internet, youtube, etc), ordered a seal puller, and two new Napa axles - which I will say are much better in all metrics vs the Duralast.

Blah blah pulled old seal, installed the new seal, tapped it in evenly to what I approximated was the correct depth (5.5mm), installed the new axles, and followed up with a diff drain and fill on level ground.

Drove 30 minutes and parked on pristine concrete, no drips when I came out. Drove home and it started spraying all over the exhaust. Great. Parked the car for another week or two while it dripped probably 1/4 of a qt in to a bucket.

Ordered digital caliper and proper axle popper. Removed axle. Inspected seal to make sure I didn't roach the new one too - all good. Tapped it evenly again another smidge and this time ensured 5.5mm depth all around with the caliper. Reinstalled axle. Topped off diff on level ground. Cleaned everything underneath to make sure I could spot even the slightest drip.

The piece of crap is still leaking. Hasn't sprayed all over my exhaust yet, but is depositing a spot the size of a softball on the ground every 12 hours.

Anyone know what the shit is going on with this thing? This isn't a tough job. I did it drunk as piss years ago with the worst of tools + crude estimations and never had a leak, but now that I have the correct tools I can't seem to catch a break. Not sure I'll even engage 4wd again before I send her to the scrap yard, but these things bother me. And it's ruining my driveway.

 

[Bad Luck]

I finally got around to replacing my 7 year old CVJ axles recently, whose boots failed last winter and were probably gunked up pretty bad from water and dirt and stuff.

I originally tried to use Duralast axles for this job, knowing well that they sucked (4runner is for taking dogs around town anymore - IDC) and was proven correct - they suck. I installed the passenger side but realized the threading opposite end was chewed up, so it had to come back out. Didn't even bother doing the drivers side, because the second duralast axle also had chewed up threads :wacko:

Removing the just-installed passenger side involved some prying and in the process I damaged the axle seal, which I had installed new (OEM) when I did the CVJs 7 years ago. Big deal, ordered a new one from the dealer (part # verified by them, the internet, youtube, etc), ordered a seal puller, and two new Napa axles - which I will say are much better in all metrics vs the Duralast.

Blah blah pulled old seal, installed the new seal, tapped it in evenly to what I approximated was the correct depth (5.5mm), installed the new axles, and followed up with a diff drain and fill on level ground.

Drove 30 minutes and parked on pristine concrete, no drips when I came out. Drove home and it started spraying all over the exhaust. Great. Parked the car for another week or two while it dripped probably 1/4 of a qt in to a bucket.

Ordered digital caliper and proper axle popper. Removed axle. Inspected seal to make sure I didn't roach the new one too - all good. Tapped it evenly again another smidge and this time ensured 5.5mm depth all around with the caliper. Reinstalled axle. Topped off diff on level ground. Cleaned everything underneath to make sure I could spot even the slightest drip.

The piece of crap is still leaking. Hasn't sprayed all over my exhaust yet, but is depositing a spot the size of a softball on the ground every 12 hours.

Anyone know what the shit is going on with this thing? This isn't a tough job. I did it drunk as piss years ago with the worst of tools + crude estimations and never had a leak, but now that I have the correct tools I can't seem to catch a break. Not sure I'll even engage 4wd again before I send her to the scrap yard, but these things bother me. And it's ruining my driveway.

At this point I would be suspecting the axle shaft. It's leaking from just the passenger side, correct? If so I would try swapping your front axle shafts from side to side and seeing what happens.

 

[hour]

At this point I would be suspecting the axle shaft. It's leaking from just the passenger side, correct? If so I would try swapping your front axle shafts from side to side and seeing what happens.

Yeah, just the passenger side. Really don't want to yank the drivers side out and jeopardize that seal too - it's been good for 7 years and two axles now without a drop. Last thing I want is both sides leaking. It's possible I didn't even do the drivers side seal 7 years ago and if that's the case it could be the original @ 265k miles.

I just ordered an "inferior to OEM" National axle seal for the passenger side and will give that a try. I suppose it's possible that there was some grit inside the diff lip, and since I only tapped it in a little further instead of removing it and reinstalling it (which would have destroyed it anyway), that grit remained. Hard to clean something out that's constantly weeping oil with the axle removed. I did wipe the inside with paper towels but it felt like the metal itself was slightly textured, as it began to chew up the paper towels and required an additional wipe with a microfiber to get the bits out.

Having a hard time picturing what could be wrong with the axle shaft, I had them side by side on the asphalt and inspected them thoroughly before doing anything (because of the Duralast adventure) and they looked identical, and the same as any other axle I've dealt with on any car. If there's a defect it's gotta be incredibly hard to pick up on. Sucks, we're finally getting winter temperatures and the last thing I want to do is.. this, again. On the plus side, I can replace a CV axle in 15 minutes now :lmao:

 

[Bad Luck]

Yeah, just the passenger side. Really don't want to yank the drivers side out and jeopardize that seal too - it's been good for 7 years and two axles now without a drop. Last thing I want is both sides leaking. It's possible I didn't even do the drivers side seal 7 years ago and if that's the case it could be the original @ 265k miles.

I just ordered an "inferior to OEM" National axle seal for the passenger side and will give that a try. I suppose it's possible that there was some grit inside the diff lip, and since I only tapped it in a little further instead of removing it and reinstalling it (which would have destroyed it anyway), that grit remained. Hard to clean something out that's constantly weeping oil with the axle removed. I did wipe the inside with paper towels but it felt like the metal itself was slightly textured, as it began to chew up the paper towels and required an additional wipe with a microfiber to get the bits out.

Having a hard time picturing what could be wrong with the axle shaft, I had them side by side on the asphalt and inspected them thoroughly before doing anything (because of the Duralast adventure) and they looked identical, and the same as any other axle I've dealt with on any car. If there's a defect it's gotta be incredibly hard to pick up on. Sucks, we're finally getting winter temperatures and the last thing I want to do is.. this, again. On the plus side, I can replace a CV axle in 15 minutes now :lmao:

It doesn't take much for an axle to leak at the seal. Since you have to pull the axle shaft on that side again to do the seal I would recommend trying to warranty replace that axle shaft. If it doesn't leak after the seal and the new shaft then you know at least one of them fixed it. You may never know which one lol but at least it will be fixed.

 

[shadow247]

It doesn't take much for an axle to leak at the seal. Since you have to pull the axle shaft on that side again to do the seal I would recommend trying to warranty replace that axle shaft. If it doesn't leak after the seal and the new shaft then you know at least one of them fixed it. You may never know which one lol but at least it will be fixed.

I have been fighting my passenger side seal too.

I "think" I have it fixed. A 60 mile round trip and no drips...

1st time I nicked the seal installing the CV.

2nd time I have no idea. It lasted about2 wheeling trips and 600 miles...

3rd one I installed too deep.

4th one I took some 1500 grit to the inner flange and cleaned it up really good. I also cleaned up the CV flange that rides on the seal. I installed this seal by HAND to the 5.5 mm depth all around. Overnight it did not drip a bit.

My best guess is that CV itself is the issue. If mine leaks again, I'm gonna swap the CV as I have cheapo Oreilly axles too.

 

[harper7]

Make sure your front diff breather is not clogged or in my case rusted shut and is working.

If it's not ,the diff will pressurize and cause leaks . Drove me crazy on a 1st Gen Taco I had years ago.:frusty:

 

[shadow247]

Make sure your front diff breather is not clogged or in my case rusted shut and is working.

If it's not ,the diff will pressurize and cause leaks . Drove me crazy on a 1st Gen Taco I had years ago.:frusty:

I'm 100 percent on that not being my particular issue. I swapped in a 4.30 front diff in September and all that is good to go. My seal leaks were entirely self induced, but I feel the pain of doing the same job multiple times and still having problems even though you feel like you did it all correctly.

 

[phattyduck]

My guess is that the shaft is a bit undersized where the seal rides. This happens often on aftermarket shafts - not just on 4Runners.

-Charlie

 

[hour]

Thanks dudes. All good things to think about that go beyond simply setting the seal in an even 5.5mm.

As of my last post this morning, it had dripped its second or third softball sized spot on my driveway, but I took it for a spin to get breakfast (5 miles each way) and it started nutting all over the exhaust again maybe 3 miles in. Odd since I actually had 16 miles on the re-set seal depth without it happening enough to hit the exhaust. I don't know what the X factor is - turning too sharp? Maybe diff pressurizing as mentioned? Parked it in the driveway and its continuing to bleed out (I keep slightly shifting where I park to see the spot)

Won't have a new seal to play around with until the 31st and it appears we'll have snow on the ground then (finally), which probably won't melt for an eternity. Going to be some shit to resolve.. had I known all of this would occur I would have had a shop do it.

Going to do all of the following when I get to taking my third stab at this:
Check diff breather
Inspect the hell out of the inside of the diff where the seal sits, use sand paper if I'm skeptical
Install new seal

If that doesn't take care of it, I will have the axle replaced.

 

[shadow247]

Thanks dudes. All good things to think about that go beyond simply setting the seal in an even 5.5mm.

As of my last post this morning, it had dripped its second or third softball sized spot on my driveway, but I took it for a spin to get breakfast (5 miles each way) and it started nutting all over the exhaust again maybe 3 miles in. Odd since I actually had 16 miles on the re-set seal depth without it happening enough to hit the exhaust. I don't know what the X factor is - turning too sharp? Maybe diff pressurizing as mentioned? Parked it in the driveway and its continuing to bleed out (I keep slightly shifting where I park to see the spot)

Won't have a new seal to play around with until the 31st and it appears we'll have snow on the ground then (finally), which probably won't melt for an eternity. Going to be some shit to resolve.. had I known all of this would occur I would have had a shop do it.

Going to do all of the following when I get to taking my third stab at this:
Check diff breather
Inspect the hell out of the inside of the diff where the seal sits, use sand paper if I'm skeptical
Install new seal

If that doesn't take care of it, I will have the axle replaced.

I would just go ahead and warranty the axle out anyway. The guys at the parts stores don't give 2 craps, and it will possibly eliminate a source of the leak. I noticed that my Non-OEM axles have a LOT more play in/out than the OEM ones, this could be contributing, along with the extra stress of being lifted...

I am going to reboot my OEM axles and put them back in sometime this year.