Non-Trouble Code Procedures

Analysis of Leakage

Clean up the leaking area enough to identify the exact source. An axle leak can be caused by the following:
^ Axle lubricant level is too high.
^ Worn or damaged halfshaft seals or differential seals.
^ Axle housing is cracked.
^ Flange yoke seal is worn or damaged.
^ Pinion flange is scored or damaged.
^ Axle cover is not sealed.
^ Vent is plugged.

Repair the axle as necessary. Make sure the axle lubricant is at the correct level.

Axle Vent

NOTE: If a plugged vent cannot be cleared, install a new vent.

A plugged vent will cause excessive seal lip wear due to internal pressure buildup. If a leak occurs, check, the vent.

Flange Yoke Seal
Leaks at the axle drive pinion seal originate for the following reasons:
^ Seal is not correctly installed.
^ Damaged seal Journal surface.

Any damage to the seal bore (dings, dents, gouges or other imperfections) will distort the seal casing and allow leakage past the outer edge of the axle drive pinion seal.

The axle drive pinion seal can be torn, cut or gouged if it is not installed carefully. The spring that holds the axle drive pinion seal against the pinion flange can be knocked out, which can allow leakage past the lip.

The rubber lips can occasionally become hard (like plastic) with cracks at the oil lip contact point. The contact point on the pinion flange may blacken, indicating excessive heat. Marks, nicks, gouges or rough surface texture on the seal journal of the pinion flange will also cause leaks.

A new pinion flange must be installed if any of these conditions exist.

Metal chips or sand trapped at the sealing lip can also cause oil leaks. This can cause a wear groove on the pinion flange and heavy pinion seal wear.

When a seal leak occurs, install a new seal and check the vent.

Differential Seals
Stub shaft pilot bearing housing seals are susceptible to the same kinds of damage as axle drive pinion seals if they are incorrectly installed. The seal bore must be clean and the lip handled carefully to avoid cutting or tearing it. The seal journal surface must be free of nicks, gouges and rough surface texture.