I have replaced this seal 2 times now on the T-case. It wil NOT seal. I'm wondering if there could be an issue with the axle it self. I mean its not like it is a hard job to do pull the wheel off drop the (2) 19mm suspension bolts, then pry the axle out then pry the seal out then I took a 2x4 with a hole to slide over the half shaft and the seal went in flush.

I drove the car around the block about 1/2 mile because it was late and brought it back and checked there was no leak. so I drive the school today and give it a 40 psi pull. I get to school and smell gear oil. Look under the car and behold it is leaking again where I replaced the seal for the 2nd time. Seal was installed properly with no damage. Axle slid on easily. The only thing I can figure is there is an issue with my axle causing the seals to go bad.

Anyone ever have any suggestions.

 

Seems common. I had an issue, and kept replacing with a new seal until it stopped leaking.

https://www.evolutionm.net/forums/ev...case-leak.html

 

Yea I have the same problem. Gonna replace the seal this weekend.

 

You might check for sharp edges on the axle itself. Emery cloth is the fix for that. The drive shaft on my DSM was so sharp on one corner it cut my finger. I don't know how the assembly plant managed to not damage the seal. Also, use rtv on the rim of the seal.

 

Thanks for the tip, I'll def make sure to look for sharp edges.