Driver Side Axle Seal Leak (again)

[Ajwit87]

Hey guys, I've been chasing a fluid leak since I got my 1990 Talon Tsi AWD Manual. I would find a very small fluid spot on the ground after leaving it for a night. After getting it on a rack and snooping around, I isolated it to the Driver Side Axle Seal. I called the Mitsu dealer, ordered a new one, and figured that would be it. So today, I install it, no issues coming apart, no issues going back together. The new seal seated perfectly, I re-install the transfer case.
It should be noted that I do NOT have the A/C Bracket, someone had used a large nut as a spacer behind the halfshaft bracket that was 7mm thick. I had done some reading on here about that spacer and it seemed that the correct thickness of that spacer was closer to 13mm. I found a nut in my shop that was 11.5mm thick, I installed that one as the spacer and discarded the old one.
The minute that I decide to top off the trans fluid, I find a slow leak from the same area. AHHHH! I remove the transfer case again, and guess where I find the fluid coming from,...driver side axle seal.
I took two pictures, one of the spacer that I used, and one of the new axle seal (don't mind the blue rtv, it was a last ditch effort after the fact). But do mind the picture of the axle seal, and notice that it has a gap on the left side (towards to rad), I dont think this is normal and makes me wonder if the spacing of the bracket is off, or maybe I have a 91-94 trans or axle and things aren't cooperating.
I can order another seal and do this job again, but I'm thinking that I'll have the same result. I did drive the car after all of this, it drives great with no issues. But upon returning, there are drips hanging from things in that area...

You must be logged in to view this image or video.

You must be logged in to view this image or video.

Any ideas or help is greatly appreciated. Thank you in advance!

 

[pauleyman]

Grab the axle and see if it moves radially. If it does the front diff has problems. Either way get the proper spacer.

 

[miliman13]

I have changed mines out recent.
have found the store bought have a slightly tighter inner diameter and a slightly larger outer diameter.

Yes i too have read that OEM is king, but not with my own experience on this.

i used a small coat of RTV on the outer ring. And axel grease on the inner ring.
Also made sure to not bottom the seals, and try and pull the seals out just a bit to let the axle dictate the depth.

Its a very frustrating nuisance i know.

2nd on the exact! distance from block based on thickness of brace.

 

[Ajwit87]

Pauleyman, thanks for the quick response.
The axle has absolutely no play, radial nor axial.
I can order a spacer, but while looking at the pictures and tech specs of the item, it no different than using a nut or washers, as long as the overall width is the same, and the mounting surface is flat to allow proper alignment. Unless someone can tell me that the spacer size is far different than 11-13mm, then I feel like it in itself, is not the true cause of the leak.

 

[pauleyman]

Is there a groove worn into the axle?

 

[Ajwit87]

No, both ends of the axle look clean and not worn at all. And by both ends I mean, the end that rides in the carrier bearing in the bracket, and the end that sits inside the axle seal at the trans.

 

[Ajwit87]

Is there any chance that someone swapped a 91-94 drivetrain into this car and that would explain the large gap around my axle seal?
I can confirm that my wiring harness is a 90 though, I have the 4 wire coil plug.