Differential Gear Oil Leak, Help Please

[Mark Eaton]

The other day I noticed a small puddle of differential gear oil under the MK4. It was barely enough to swab with my finger. Smell is unmistakeable. That was about 450+ miles, car running excellent. I rolled 600 miles Friday. Yesterday I put her up on the lift to investigate.

https://thefactoryfiveforum.com/attachment.php?attachmentid=126198&d=1586659314

There is a bead of gear oil leaking around the passenger CV axle and center section seal. My first thought was that this a a problem with the seal in the center section. But then it dawned on me that maybe the gap between the axle and the Center section it too much?

https://thefactoryfiveforum.com/attachment.php?attachmentid=126216&d=1586710045

https://thefactoryfiveforum.com/attachment.php?attachmentid=126218&d=1586710649

The manual says the gap should be about 1/8", it is clearly more than that. Could this be causing the leak? I'm not sure if the axle backed out or if I never had it correct. The DS axle is much closer to the center section. Sorry, no photos.

I suppose the first thing I need to do is get that CV axle seated in closer to the center section. Not sure how much of the IRS assembly I will have to take apart to accomplish that.

Any input is appreciated.

-Mark

[65 Cobra Dude]

Mark,

Hopefully none. There is slack in the cv joints and there should be enough to tap the axle in at the rear end side. You should here a clunk when it is seated all the way. You can either try prying or tapping with a brass drift but don't rip the boot.

Henry

[Mark Eaton]

Thanks Henry, I backed the nut off of the CV axles and tapped them in gently with a rubber hammer as per the manual. Then I leveraged the axles into the center section pivoting off of the lower control arm being careful not to tear the boot. They each "clunked" in nicely! In retrospect I'm pretty sure I set them up improperly from the beginning. Part of the problem is that there is not a good photo in the manual of what they should look like. Interestingly, the car has been performing really well despite improperly seated CV axles.

https://thefactoryfiveforum.com/attachment.php?attachmentid=126270&d=1586740736

https://thefactoryfiveforum.com/attachment.php?attachmentid=126269&d=1586740718

[65 Cobra Dude]

Glad it worked out Mark!

Henry