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I have a 99 Ranger that has a slow leak from the seal where the drive shaft goes into the transmission.
I have taken it in (under an exteneded warranty) 3 times now, and it looks like it is still leaking.
Hoping that the mechanic will be open to suggestions, is there a trick to know when replacing this seal so that it doesn't keep leaking? (They have replaced the rubber seal once, and the metal one twice.)
There is an "extension housing seal" that is located up near where the driveshaft attaches to the transmission. There is also an "extension housing bushing" underneath that seal. These are probably the things you are talking about that have been already been replaced. Seems like a straightforward job, except for three noticeable "quirks":
First, according to my '98 Ford Manual, "When installing [the bushing], the lube hole in the extension housing bushing must be aligned with the lube groove in the extension housing. This groove is located at the 3 o'clock position when viewed from the rear."
Secondly, the Manual says to "Inspect the counterbore of the extension housing for burrs. Remove any burrs from the extension housing counterbore with an oil stone."
Finally, regarding the seal itself, the Manual says to "Position the new extension housing seal with drain hole in the 6 o'clock position."
So those would be three things that a mechanic should pay close attention to when performing this kind of repair.
Also sometimes a groove will wear into the seal surface area on the shaft that may not look bad but is enough to cause small leaks. Seating the seal just a little farther in or not quite as much as the old seal (depending on where the original seal was set) will sometimes stop the leaks. I like to pack the inner lip of these seals with grease to act as a heat sink for the initial runup to keep the seal from getting hot until the oil gets there.
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