Drivers side diff seal NIGHTMARE

I'm having insane issues with the drivers side diff seal. None of the seals leaked, then replaced the Cv axles and BOTH sides leaked. Replaced both seals and did the ecgs bushing. drivers side still leaks fairly bad. Replaced seal again with same issue. Replaced cv axle tonight and it's STILL leaking. WHAT THE FUCK.

Used Napa cv axles. The odds of two being the issue seems slim

 

I would try an OEM axle and seal. Seems to be your only choice now.

 

If you bottomed out seal you went too far, needs to be flush with housing, ask me how i know? I would also go oem on this one, iirc they werent too bad $

 

^this,

I had the same problem. But then I reinstalled a new seal flush with the housing and it stopped leaking.

 

Flush on drivers side ? I've been told that the drivers side needs to bottom out? Either way I've tried it both ways. All oem seals. This is getting very expensive.

 

Do you guys really think it's the cv? The passenger side leaked when I first installed them...the. I put a new seal on that side and it hasn't leaked since.

Could this be because of the ecgs bushing ?

 

The Napa cv axles were suppose to be "good" they look good and look oem reman

All the seals have been oem

 

Anthony, I had @Speed Freek help me when I did my ECGS bushing and I could have sworn that he pointed out that you could not bottom them out. When I dropped the front diff when we rebuilt the truck last year I replace the seals again with OEM and installed them flush and I have had zero leaks.

 

The first time i put them flush. The last time I tried bottomed out on drivers side. I have a spare seal that I might throw it in. Or I might buy a oem cv axle and then do it.

Only takes about 30 minutes now lol

 

did you slip the boots up a bit and spray the axles with some self etch primer & paint ? If not the next time you pull them do it or the axle will have an insane amount of rust incredibly quick...happened on our T4R.

 

I will do that if I keep the axles. Only thing I did was move the boots down a bit.

You think it could be the axle causing the leak? Seems like the odds of two of them being faulty is slim. Passenger side is doing great.
When I installed the bushing I left it sticking out about 1-2mm

 

Is anybody using the old seal to drive in the new one after some minor trimming, I did this as I used to do it on honda trannys all the time. Replaced the driver side during ecgs install, no leaks here.

 

22,000 miles.....Covered under warranty?

 

If you have a dial caliper check old vs new where the seal rides

 

I use 2" pvc pipe

 

Yeah I did that too, really easy to mess up the seal if you don't protect it. No leaks.

 

I used 2" pvc coupler. New seal in flush. No issues yet but only gone about 100 miles so far.

 

That sucks. Sorry about that.

I kept the seal flush, used an oem cv, and cleaned the diff breather.

No more leak.

 

Maybe bushings not in far enough??

 

It sounds like you are doing everything right. As said above, mic the aftermarket cv as there have been reports of smaller OD at the sealing surface.

Grease the seal before you install the CV.

What do the leaking seals look like when you pull them? Is the spring out of shape? Is it leaking between seal body and diff tube? Do they pop out too easy shen removing them?