03 Cobra IRS Axle Seal Leak After Replacement

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Had a pretty good leak from my Pass. Side axle seal (flinging all around).

Popped the axle out and replaced the seal (with the bearing/seal kit from American Muscle). Destroyed one of the new seals in the process but got one in there.

Drove the car about 150 miles so far and I still have a leak coming from the seal. It's not flinging, but I have a couple of drops on the ground and a little bit of a seeping from the seal.

Lubed the seal with diff fluid before re-installing the axle.

Noticed that there was a little bit of a groove in the snub part of the axle (not deep, but could feel "waves" for lack of a better description), i cleaned all the grime and crud off the snub before reinstalling axled and lubed it with diff fluid.

Any thoughts on the leak? I have read about having to slightly sand the grooves out of the axle where it rides against the seal? Probably will just wait until spring to deal with it but would like to hear some 2nd opinions.

Thanks!

[jaa55]

Taking some Emory cloth and cleaning it up shouldn't hurt. If it's cut a deep groove in there it might still do it anyways. Seal definitely in the right direction?

Do you have a caliper to check any of the diameters? If the bearing was going bad maybe you still have excessive clearance with the axle?

[somethingclever]

yes it could be attributable to a bad axle brg.

Definately clean up axle with emery cloth - 5 min of hand polishing should be all that is needed unless grooves are really bad.

I don't understand how you screwed up one seal but got one in? There is only 1 seal in the diff on each side...or do you mean the kit comes with one for each side and you fubar'd your first attempt at the leaking side.

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yes it could be attributable to a bad axle brg.

Definately clean up axle with emery cloth - 5 min of hand polishing should be all that is needed unless grooves are really bad.

I don't understand how you screwed up one seal but got one in? There is only 1 seal in the diff on each side...or do you mean the kit comes with one for each side and you fubar'd your first attempt at the leaking side.

Yes, sorry that wasn't clear. I messed up first attempt. And the grooves aren't bad, just barely noticeable. Maybe over winter I'll take out the axle and clean it up as I may not be driving it much more this year.

Will keep you guys updated on what I find out.

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Bumping this because now I am stumped. The seal was leaking after the first time I replaced it, so I crawled under and saw that the IRS had play in it and the bushings were just shot, I could see fluid seep out when I pushed on the pumpkin.

I replaced both seals, both bearings, added IRS brace and poly bushings. Cleaned up the axles with a red scotchbrite pad to try and smooth out any grooves.

100 miles later, leaking again, same side as before (passenger side). Is there something else I am missing? Anything else I can try before I drop $400+ for a half shaft?

[somethingclever]

Are you over filling it?

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Are you over filling it?

Thought about that but, since it's a PITA to drain and fill in the car, I triple checked the level before I put it back in the car. My only other thought is that maybe the axle is too grooved and fluid is getting past. May find a cheap reman axle to pop in for 50-100 miles before I spring for an OEM.

[somethingclever]

should be easy to find a good OEM unit on svtp for cheap.

Did you take any pictures of the grooves?

Is there any slop in the inner stub shaft when it is inserted in the diff? (indicating worn axle brg)

With constant leaking after a new seal, slightly marked/grooved stub shaft, I am betting on a prematurely worn axle bearing.

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should be easy to find a good OEM unit on svtp for cheap.

Did you take any pictures of the grooves?

Is there any slop in the inner stub shaft when it is inserted in the diff? (indicating worn axle brg)

With constant leaking after a new seal, slightly marked/grooved stub shaft, I am betting on a prematurely worn axle bearing.

There is slightly more play on the pass. side (leaking) than driver's side (dry) when I crawled under, but I wouldn't think enough to cause an issue. Only problem is, I had the axle bearings replaced along with the seals, since when I replaced only the seal last year it was still leaking. Is there anything else inside the diff that can cause it? Both axles clipped in without issue, so I don't think it's riding out of the housing or anything.

Also, I don't think I have a pic of the groove, but I may pull it back out and hold a straight edge on it to see how it looks. I've done it enough times I can prob have the axle out on the floor in 20 minutes.

[Dan B.]

With constant leaking after a new seal, slightly marked/grooved stub shaft, I am betting on a prematurely worn axle bearing.

So......are you saying he has premature leakage???

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So......are you saying he has premature leakage???

Damn man, I'm only 31... I don't wanna worry about premature leaking from my rear end!

[Dan B.]

Sounds to me like you've been abusing your stub shaft if it's got a groove on it...........maybe you spent too much time hand polishing it.

[somethingclever]

insert thread derailment meme here.



And no - there is nothing else to replace to keep it from leaking. If the brgs are good, the stub shaft good, and the seal is good....that's it.

So...either you are overfilling it, or the shaft is scored enough to be a problem.

Don't pull it to take a pic...pull it and insert a replacement.

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Update: I checked the level before putting the diff back into the car and it seemed to be right where it needed to be. It leaked the first few times I drove it, but not the last 4-5, including a 250 mile road trip. So MAYBE there was a little bit of overfill but it seems to be good to go now. Maybe I should stop second-guessing myself!

[PaxtonShelby]

Glad it's worked out Dan.