Replaced My Axle Seals 3 Times in 2 Months. What to do Next?

[Sherwood4Runner]

My turn with axle seal problems :/

Drivers side seal started leaking about 500-1000 miles after I replaced the rear diff with Mobil 1 synthetic 75w90 gear lube. So I replaced the driver side o-ring and inner seal.

Two weeks later it's still leaking so I buck up and purchase the replacement parts for the driver's side axle shaft, drop it off at a shop, and have them press on the new parts. Turns out all the old parts, including the bearing were still in excellent shape so they returned the old parts to me. (money well wasted). I replaced the inner seal again at this point.

Three weeks later, driver's side is leaking again and now passenger side is starting to leak slightly. So I pay a shop to replace both side inner seals and o-rings again, because I want someone other than myself to be accountable if they fail again.

Here I am less than a month later and my seals are leaking yet again.

The only thing I can figure is that I am running the wrong viscosity/weight of diff fluid or something in the synthetic fluid is causing the seals to leak. I haven't had the truck off road since the Spring so the seals aren't getting bent.

Any insight from anyone else that has run into this problem??? I'm tired of throwing money at this and having to replace my rear shoes.

 

[thebrandon]

I had a similar experience when I did my axle seals. My BIG mistake was not using OEM Toyota axle seals. These are the only ones that seem to do the job. Other than that if the seats are pressed on too far, it will not seal correctly. A slightly bent axle housing or axle will cause them to leak. In some cases even tires that are not balanced correctly that "shimmy" too much can cause them to fail, as well as old wheel bearings with too much play in them. The axle seals are horrible on these trucks.

This shop you are taking your 4runner to, is it a dealer or??

 

[mmml4]

My BIG mistake was not using OEM Toyota axle seals. These are the only ones that seem to do the job.

X2 on the OEM seals. Had the same problem with my sons 22RE front main seal, and rear pinion seal after two aftermarket seals I put in a Toyota seal and no more leak. I don't understand it but now I only use OEM seals.

 

[Drcoffee]

No, your viscosity is correct. The retainer isn't getting deep enough into the seal. Pull the axle out and put bearing grease on the retainer and reinsert the axle. Spin it and pull it out. If the ring isn't in the center of the retainers shoulder, it's not sealing. On mine, the seal was just touching the bevel and nowhere near the shoulder. Here's what I have done to fix my leaking axle seals and several others have done the same with great success. Be sure to watch the video.

solution to leaking axle seals 3rd Gen

Check your axle housing vent too.

 

[audiness]

I replaced my axle seals, and now my rear drum brake keeps sticking....:ak472:

 

[Drcoffee]

I replaced my axle seals, and now my rear drum brake keeps sticking....:ak472:

Either you didnt clean the brake shoes well enough but probably because the seals are leaking again.

 

[Sherwood4Runner]

I had a similar experience when I did my axle seals. My BIG mistake was not using OEM Toyota axle seals. These are the only ones that seem to do the job. Other than that if the seats are pressed on too far, it will not seal correctly. A slightly bent axle housing or axle will cause them to leak. In some cases even tires that are not balanced correctly that "shimmy" too much can cause them to fail, as well as old wheel bearings with too much play in them. The axle seals are horrible on these trucks.

This shop you are taking your 4runner to, is it a dealer or??

I've been taking it to a local shop and providing all the OEM parts and fluids myself. So basically using them for labor since I have run out of time and money to throw at these seals without someone being accountable for them haha.

 

[Sherwood4Runner]

No, your viscosity is correct. The retainer isn't getting deep enough into the seal. Pull the axle out and put bearing grease on the retainer and reinsert the axle. Spin it and pull it out. If the ring isn't in the center of the retainers shoulder, it's not sealing. On mine, the seal was just touching the bevel and nowhere near the shoulder. Here's what I have done to fix my leaking axle seals and several others have done the same with great success. Be sure to watch the video.

solution to leaking axle seals 3rd Gen

Check your axle housing vent too.

Thanks drcoffee! I'll examine the retainer depth and use the grease trick on thursday when the mobile mechanic comes out to try and remedy the situation. Breather was extended and replaced recently too. Great advice

 

[Yoterman87]

are you replacing both inner and outer seals?

 

[Doc2012]

Try this. You spend the 138, upgrade it all.. Why not. Gonna have it apart again anyways...

Haven't had a problem with these.

Rear Axle Service Kit ('79-'99) | Inchworm Gear

 

[Mike&Ike]

They also can fail because of a bad bearing. Replace the bearing.

 

[Drcoffee]

They also can fail because of a bad bearing. Replace the bearing.

Mike, It sounds like the bearings were changed.

Two weeks later it's still leaking so I buck up and purchase the replacement parts for the driver's side axle shaft, drop it off at a shop, and have them press on the new parts. Turns out all the old parts, including the bearing were still in excellent shape so they returned the old parts to me. (money well wasted). I replaced the inner seal again at this point.

 

[Sherwood4Runner]

are you replacing both inner and outer seals?

Both inner's and outer's have been changed at this point, the inner multiple times. Outer is only a dust boot I believe and doesn't play a role in keeping the gear lube contained.

 

[98Roamer]

Outside is a dust cover.

Embarrassingly I put my in backwards and leaked within a month. Put them in correctly and they've been fine for several years.

I also used Timken seals both times.

 

[98Roamer]

No, your viscosity is correct. The retainer isn't getting deep enough into the seal. Pull the axle out and put bearing grease on the retainer and reinsert the axle. Spin it and pull it out. If the ring isn't in the center of the retainers shoulder, it's not sealing. On mine, the seal was just touching the bevel and nowhere near the shoulder. Here's what I have done to fix my leaking axle seals and several others have done the same with great success. Be sure to watch the video.

solution to leaking axle seals 3rd Gen

Check your axle housing vent too.

Huge applause for this thread and video, very educational. Thank you!

 

[SR587]

the pic drcoffee posted is correct. whoever is replacing all your stuff isnt doing it right. you cant just throw it all on, there are certain places the abs ring and spacers need to go to properly seal. i had the same issue with my 99 and two toyota dealers couldnt get it right until the last one, seems to be holding up but that was before i was a toyota tech so didnt do it. now that ive done a few of them, its super simple

 

[Sherwood4Runner]

Well guys, had my mechanic come out to look at the seals again today. And after looking at where the retainer was on the axle we found out why it was leaking. The retainer isn't touching the seal AT ALL. The shop I took my axle to a few months ago pressed the retainer on too far so there is about 13mm gap where this image shows 5mm:

<img src='http://imageshack.us/a/img141/772/retainer.jpg' border='0'/>

So later this week I am going to have my retainer rings on both sides reversed and set closer in to fix this leak once and for all!!!

Thanks for all the help. Images were especially helpful.

 

[SR587]

the gap you're looking for is between the abs ring and the shim thats closest to the wheel studs. there should be a 4mm gap. just take it to the toyota dealer, and a good one at that so someone that knows how to do it does it. or ill do it for cheaper ive done a few when i was a yota tech. they're easy if you know what you're doing

 

[SR587]

i just re-read what you wrote. you shouldnt go by that measurement because that part of the axle isnt consistent. you measure what i said earlier. between the abs right and the shim closest to the wheel studs. that way when there's that 4mm gap, itll place the shim you posted in the perfect spot on that seal

 

[Drcoffee]

i just re-read what you wrote. you shouldnt go by that measurement because that part of the axle isnt consistent. you measure what i said earlier. between the abs right and the shim closest to the wheel studs. that way when there's that 4mm gap, itll place the shim you posted in the perfect spot on that seal

I hate to contradict you here but 4mm between the outer retainer and the ABS exciter ring isn't enough. It still won't reach the seal. He has 13mm of space inside of the retainer and 4mm will leave him 6mm (1/4") shy of where he needs to be. This picture is of my axle before I figured it out and it easily has 4mm+ between the two you mentioned and the retainer wasn't even in the same zip code. Look at the 2nd picture and you'll see a gap between the ABS ring and both retainers.

A big problem with our axle housings is that the cavity within the seal is so very shallow that you need to sink it as deep as possible without hitting the housing. Which unfortunately is only a few mm one way or the other. By flipping the retainer around you get more room to play with and the retainer doesnt need to be in as deep to get a good seal.

The space between the arrows is all the room you have to place the retainer (seal lip and housing internals). Before I buttoned up my axles I inserted a used retainer into the seal mounted in the housing. It only went in 11mm. The seal is 9mm thick and the retainer is 13mm thick. The best you can expect from the original configuration is to get the seal lip onto 2mm of the retainer's shoulder before it will bottom out on the housing. Confusing I know.

Sherwood4Runner,

Do yourself a huge favor. Get some RTV that is gear lube resistant and seal the seal to the housing and the inner retainer to the axle. Those are two other locations that the gear lube can leak out. something like this: