Your installing your swing axle seals wrong!!! Read this..

[Rockbound]

Ok so I’ve searched and read just about every thread on leaky axle seals. I’ve been battling seals for years since I built my buggy. Constant leaks, tried everything I read but never saw, or maybe just didn’t pay attention to assembly order of part if it was written somewhere. I’ve always installed according to the explained view. But finally after the 4 time replacing them something clicked in my head.

So. According to this view here was my solution and order of install. Finally no more leaks.

After bearing is installed and after new seal and splash washer installed in cover.

1 - install #7 washer
2 - install #8 sealing ring
3 - install #9 sealing ring
4 - *** DO NOT INSTALL OUTER SPACER ON AXLE SHAFT.
5 - install outer spacer into oil seal in the cover on your bench
This ensures the seal is properly seated around the outer spacer and you can
see what’s going on with the seal, instead of crushing it when installing cove over it on the axle.
6 - install paper gasket
7 - install cover and outer spacer onto axle shaft and tighten cover

[modok]

good tip

[nsracing]

all you gotta do is pay attention to what you are installing. many just slap the parts and see what leaks.

[esde]

There is also the issue of mismatching axle tubes, backing plates, and bearing retainers. There are several changes in the bearing bore depths, and backing plate thickness. Use the wrong combo of parts and the big o-ring is not going to seal the deal. Spending a few minutes to polish the seal spacer is also always a good idea.
SD
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modok wrote:
Bent cranks are silent but gather no moss. I mean, ah, something like that.

[DeathBySnuSnu]

Firstly.... I am not a mechanic..... just a hobbyist.

On mine..... It leaked.
When I pulled it down I did notice the small o ring was not crushed.... but did not think anything of it at first.

But when went back together with a new seal kit I do notice the spacer bottomed out before feeling spongy on the ring.
Come to find out the o ring was too thin in cross section diameter. Bought another kit, still not right. Dug through the junk pile and all the spacers I found all had the same chamfer. I got some empi spacers and the chafer was smaller and the length longer. I lathed on them until I felt I had the right amount of crush between that chamfer and I ring. I think I used a generic o ring out of the assortment kit at my employment.
Since that time I have helped a couple friends and theirs was the same way.

So
check the crush on the small o ring.
if you have a disc brake kit then check the crush on the large o ring also.

especially on a swing axle.
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[Busstom]

[DeathBySnuSnu]

I did get from a couple different sources.
The most expensive was the same as the cheapest except for the name on the lip seal. I am talking fit only, do not know durability.

The parts that came closest to fitting was empi seal kit and the empi spacer.

The width/depth of the chamfer was still to large.
I think I picked a generic o ring and trimmed the face true and cut the chamfer until it fit the way I wanted.
The empi spacers were too long and I had plenty material to work with. They were fairly hard but not as hard as stock.

Now I do think this is all swing axle.
I have since built my IRS and even though a lot of it is empi most of it measured out and did not take much to fit.
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[Root_Werks]

Putting the spacer in the seal before placing the hub on the axle is a good tip. Learned that number of years back. Easy for the spring in the seal to fold or pop out.
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When I set my timing, why do I flush, then take a pee?

[petrol punk]

[sjbartnik]

[esde]

[clonebug]

I ordered a bunch of new o-rings online that were a higher quality than the ones in the kits. I replace the large o-ring with one from oringsandmore.com and it does seem to help with leakage. My last install has held for 3 years now.

There are also differing levels of quality between the brands of axle kits you can buy.
I've also found the seal is very sensitive to the installation of the spacer. It is very easy to damage and roll over the seal lip. Putting the spacer into the seal before installing the bearing cap helps immensely in not damaging the seal during install.
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[EVfun]

[esde]

strange timing, that one of the new axle seals on my rebuilt split case trans is dripping.. and I was very careful during the installation. Check it out:

The o-ring behind the spacer got pinched into the little gap between the shim #7 and the axle. I don't know if it's a problem with the shim or O-ring, the spacer is stamped VW so I assume it's got the correct bevel to fit against the o-ring. This is a Wolfsburg West seal kit, and to be honest I do not like them.
Here's the spacer and o-ring after picking it out.

My current plan is to leave the rubber thats stuck in the shim, and fit a new o-ring to see if it still leaks. If it does I'll R&R the whole thing with new shims and seals.

[EVfun]

[neil68]

#7 washer should be 0.75 mm thick as per OEM.
I had some aftermarket rebuild kits supplied with 0.5 mm washers and had an annoying leak. After buying new German kits with 0.75 mm washers, the leak was fixed:)
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Neil.

Der Kleiner Rennwagens
‘68 Beetle 2332 cc, 204 WHP
12.5 seconds @ 108 mph
Dynojet Test: https://www.youtube.com/watch?v=M9B_H3eklAo

[Fender38]

I learned how to do this properly a number of years ago from watching a YouTube video. It was from a mechanic in the UK. And just like the diagram you posted, I remember the paper gasket was one of the last parts installed, which I thought was strange at the time. Well, mine have never leaked a drop after that. So, I'm a believer.