Just installed a new clutch and new axle seals in my existing/good manual tranny with my existing/good axles, and refilled the fluid using the side hole as normal... and as I'm reconnecting everything, I notice that my axle seals on both sides are seeping transmission fluid.

1.) the axles both 'popped' into the transmission, and do not come out (both sides)
2.) both inner joints of axles do wiggle aka 'pop in and out' of the transmission about 1/8" ~ 1/4"
3.) both axles are locked in, and don't actually pop out unless I use a pry bar
4.) the axle seals are seated all the way in the transmission using a block of wood while the transmission was out
5.) I put a tiny bit of grease on the inside of the seals where the axle goes through

What am I doing wrong? Are the axles not in all the way? Is there or is there not supposed to be in-and-out play? Should I take the cross member / control arms / tie rods off again to completely remove axles from transmission and try at a different rotation?

It's been nearly 10x years since I've had to replace a transmission (this would be my 3rd or 4th time though), and these leaking @%$^@!%$#& axle seals are pissing me off... help?????

- J

I won't be much help, I've only replaced the seals once. Used the same method as you except it was a piece of pipe roughly the same od as the seal and tapped it in very gently/easy, didn't use any grease though. Perhaps the seals got damaged while installing...hard to say man.

I contributed to the Wiki.

There will be a little play in the axles, that's ok. The axle surface that is contact with the seal should be smooth, that's the main thing. I have never put grease on an axle seal and never had had a leak from them. I don't think it's appropriate to grease them.

2gnt: '99 RS-T, killed by a toyota, pending rebuild...
Daily: Volt
Daily #2: '99 EVG ebike- STOLEN by PEDRO

No, the seals aren't damaged and do grab around the axles cleanly... Yes, the axle surfaces are nice, smooth, and shinny. It was the little bit of in-and-out play that was concerning me, just didn't think or remember to put them in 'dry'.

I wonder if me greasing the inside ring/seal that touches the axle is allowing the fluid to seep out through or around the grease, and not letting it actually seal. If so, I wonder if I'll be able to clean the grease off well enough for it to not seep the fluid anymore.

I'll go ahead and pull the axles again this weekend and see if I can't get the little bit of grease off... if I can't, then I'll have to pop them out and replace, which will be a pain in the ass while still in the car.

- J

Well I popped the axles and the grease was like slime, diluted with the tranny oil... cleaned it all off, and wacked the lip of the seal a few times with a large hammer / tiny sledge to make sure it was completely flush all the way around too. And now it's not leaking anymore, ####!

!! No grease !!
- J

Glad you got it sorted out man.

I contributed to the Wiki.

Nice I absolutely hate leaks. I recently changed every seal on the engine except the internal oil pump o-ring - so sick of smelling oil burning on my down pipe!

2gnt: '99 RS-T, killed by a toyota, pending rebuild...
Daily: Volt
Daily #2: '99 EVG ebike- STOLEN by PEDRO

Wow, that took a lot of effort... was the result an oil-free smell?

- J

It's 95% better. Next thing I want to do is take the breather filter off the valve cover, and weld in a bung pre-turbo so that I place a hose directly from the cover to the intake. That's the only other spot I can think of that would generate fumes.

2gnt: '99 RS-T, killed by a toyota, pending rebuild...
Daily: Volt
Daily #2: '99 EVG ebike- STOLEN by PEDRO

Yeah, I've also just got that going to atmosphere... I thought about what you're describing also, but question the impact it would have. I don't really have any piping before my turbo, just a small downward "J" and an air filter.

Right now I've got a small oil leak coming from 'above' the oil filter that's driving me nuts (have no idea how or where, as I redid the valve cover and oilpan/crankscraper gaskets), but that's it.

Now I think my axle seals were fine actually, but I overfilled the fluid a little bit (I measured 2.2 quarts and plugged it up even though it wanted to dribble out hole still)... I jacked car up and popped driver's wheel to check fluid level after a week and repeated... but let it dribble a bit. I had a leak the very next morning, but that's it... bone dry since then.

- J

If you have an oil leak above the oil filter and your valve gasket is not the culprit, it may be your crank position sensor seal.

2gnt: '99 RS-T, killed by a toyota, pending rebuild...
Daily: Volt
Daily #2: '99 EVG ebike- STOLEN by PEDRO