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The left drive axle is leaking at the seal. The problem is not the seal. There are no unusual noises and the transmission performs normally. I rebuilt the transmission about 9 months before the leak started and I wonder if I forgot something.

I have removed the drive axle several times over the years as I was doing various repairs. Usually the drive axle is sort of tough to remove. I would have to pry it out. When I recently replaced the seal, the axle came out easy. As I was putting it back together, I noticed that when the spline is fully inserted that there still is some wobbling. I tried to look inside the differential as best as I could through the axle opening to see if there was a problem, but I did not see anything obvious. I did notice that there was no c-clip on the axle spline, but I did not see where one would go either. I felt around inside the differential to see if there might be an internal clip to hold the axle, but I could still not figure it out.

Of course, the new seal did nothing and probably is leaking worse than before.

I am fairly certain that the wobbling is causing the leak. I hate to pull the transmission for disassembly just to learn that I could have fixed this with it still in the van.

So, I guess my first question is what normally locks the axle splines in this particular transmission? It seems that the internal spring of the inner CV keeps the splines fully engaged, so I am beginning to wonder if a c-clip was used. I have never seen an axle spline without a c-clip (internal or external), so this just does not seem right. But, again, I don't see where an external c-clip could be fitted on the axle shaft. It seems like it would have to be inside the differential.

If there is no c-clip on this application, I guess the only other possibility is wear in the differential.

If a c-clip is used inside the differential, could I insert it through the shaft opening or will I have to disassemble?

Thanks for reading, MP  

there are axle support bearing/seal assys that press in where the seal goes...   some are retained by a plate that comes with it...  they do work...  they are not available at most parts stores..  you have to get them through an automatic transmission parts seller.. usually...

here is a pdf file with pictures of the transmission parts...  pictures not drawings..

http://www.amtrans.nl/A604-_A606-_42RLE.pdf

item 275 is the axle support bearing and seal...   they really do work....   there are tools to extract the differential side bearings in place and replace them... but it might be easier to drop the steering cross member and drop out the differential...

there is also a clip to stop the cross shaft in the differential from sliding out..  probably a good thing to install too many have had the crossshaft slide out.. if you are moving ... it will destroy the case.. and everything else...  

The spring is what keeps the axle in the diff.There is no clip.You must have overlooked some wear in the diff when you did the trans.It could be the side bearing is shot but more likely the diff housing is worn.Dont drive it too much they are notorius for the spider gear shaft spinning and coming out and punching a hole in the case.  

Thank you for your reply. Great link. Much better than drawings. There are two good transmission jobbers in my area. Getting it should not be a problem.

Surely the support bearing isn't designed to compensate for a bad differential bearing. Is there other less critical wear for which this compensates? Or, is this just a common issue for an otherwise healthy transmission? I guess my real question is if this is used to hide the real problem, which will have to be fixed sooner rather than later?

Before I install the support bearing, I want to make sure the differential bearing isn't going to turn to dust. Can you tell by prying on the differential through axle opening? It seems like some movement might be normal. I guess I could remove the cover and check for play. Removing the cover is not major surgery.

I checked into that tool to replace the bearing and it is around $400. I can't really justify it even though I very much enjoy buying tools. I thought about dropping the steering, if I was going to have to remove the differential. I couldn't decide which would be faster between the steering or transmission taking into account the ease in working on the transmission on a bench. Dropping the steering is probably the way to go.

MP  

Thank you for answering. That clip thing was bugging me. I just assumed all transmissions used some sort of c-clip to retain axle shafts.

My previous post touched on this, but I'll ask you in this reply. How can you tell if it is case wear or bearing wear? I don't hear any of the noise you would expect in bearing wear. So, is the seal/support bearing assembly discussed to compensate for case wear?  

It is not case wear. The 2 possibiltys are a bad diff carrier {side} bearing or the diff housing itself is worn where it supports the axle and  the spider gears are shot which allows the axle gears to flop around.I would pull the trans.   thats going to be the least headache.If your housing is worn you can get a used one from a used hard parts retailer for no more than $70.Of coarse thats with a lift and a tranny jack. If i was on jack stands in my driveway i would have to rethink whether to pull the whole trans or not  

I had the same problem. It turned out to be a weak spring in the upper cv joint. What was happening was the slpined shaft would pull out far enough to leak fluid like crazy. I replaced the axle and have had no leaks since. I hope this helps.