Leaking axle seal question

Just replaced the driver side front differential seal and axle on my 2005 V6. It is now leaking worse than before I changed the old seal. I think I may have installed the seal incorrectly. The old seal was installed with the lip (pointed to in the picture) flush with the housing so thats how i installed the new one (the old seal has always had a slow leak since i bought the truck used). Is that the correct way or is the edge of the seal supposed to be flush with the housing?

 

General practice:
pack the backside of the seal where the spring sits with trans gel, or grease if thats all you have...
That keeps you from f'ing up & popping the spring out of the seal....
Were you using a seal installer, large socket, etc or just hammering on the seal?
If it were me, ide run the main body of the seal flush with the case.
Running the extended lip flush with the case may install the seal excessively deep.

The benefit of working on the same stuff day in & day out, you know what its suppose to look like so you know what's right & what's wrong.....

 

There might be too much play in the axle.

All tacoma left axles have play but it gets worse with age.

You may need the ECGS bushing to fix it and the leak.

 

I've had the ECGS bushing installed for a few years now. I installed the new bushing by putting the old bushing over it and lightly tapping it in with a hammer.

 

I wonder if I just installed it too deep in the recess and the actual seal portion is not engaging the axle surface enough

 

Outer edge of the seal should be flush with the housing



20 year-old diff. Make sure the housing bore is smooth and free of rust, to prevent leaks at the seal OD. Plug the hole with a plastic bag and sand down any rust. You can also put some sealant on the seal OD during install; wait for the sealant to cure before filling diff oil.

 

Thanks. Picking up a new seal in the morning

 

+1 a rust lip can cause this.

I install most seals by hand, sometimes I use old bearing races, or even the old seal to push it in. Sometimes a 1/2" extension works. But I go flush with tacoma diffs.

 

As stated, look at the cv shaft where the seal rides, make sure its not grooved.
If it is & the groove isnt huge it can easily be cleaned up with a scrotchbite pad, find steel wool, etc...