Right Rear Output Axle Shaft Seal Leak (Chamfer Houseing)

Some customers may comment that the rear axle is leaking fluid.

Confirm the condition following the Rear/Front Axle Lubricant Leak Diagnosis in SI. A technician may find a fluid leak from the right side output axle shaft seal. The seal may come out of the axle housing when the right hand drive axle flange is removed.

The axle shaft seal bore in the housing should have a beveled edge or chamfer. This lead-in chamfer helps protect the outer diameter of the seal during installation. In some vehicles, the chamfer may not have been machined into the housing. In these cases the seal bore will have a sharp, squared-off edge.

Notice: Be careful not to damage or nick the inside axle housing seal bore when removing the seal. A flat bladed tool may be used on the outer edge of the seal ONLY. DO NOT use a pry bar.

Important: DO NOT replace the complete axle assembly for this condition.

To obtain a proper chamfer for a good seal installation, deburr the right side axle housing seal bore using a standard deburring tool (1), such as DEBUR300 from Snap-On, EO1000 Edge Off from Noga, SHAVIV by Vargus or the equivalent.

It is necessary to remove the exhaust system and the right rear wheel drive shaft. Refer to Rear Axle Shaft Seal and Rear Wheel Drive Shaft Flange Replacement in SI to allow room to perform the following service procedure:

1. Place a clean, lint-free shop towel inside the right side differential seal bore to protect the bearings from any chips created by this process.



2. Using a deburring tool, chamfer the outer edge of the right axle housing seal bore (1) approximately 3-6 times or until a smooth chamfer of 1.5 mm (0.06 in) depth is created.
3. Clean off any chips from the housing area.
4. Remove the shop towel.



5. Visually inspect that all chips have been removed and that no burrs or sharp edges remain on the chamfer (1).
6. Follow the regular seal installation procedure. Refer to Rear Axle Shaft Seal and Rear Wheel Drive Shaft Flange Replacement in SI.
7. Check and top of rear axle fluid as needed.

For vehicles repaired under warranty, use: