okay, 3mos later and a few thousand miles, no leaking. Replacing the rcv bird and shaft did the trick. Don’t know what the issue was there, but planning on using their warranty and see if the next set is better. Thanks for everyone’s help
Definitely longer flanges. Pulled out as far as possible and can only put the clip on the outer groove.
Having said that, I just put the original axle in and gonna drive it a few thousand miles and see if I have the same issue. The seal looked to be in great shape. Spring was still in and...
Thanks. Didn’t know that. Regardless, used the outer groove that I used on the newer axle matches the length of the oem axle.
Just inspected the newer axle a little further. The shaft is loose at the star and seems like it can go in another 1/8”
Okay, getting around to the work. Pulled the axle. Its MUCH stiffer than the original (the lower one in the image). Also, looking at the wear pattern on the newer one, it looks like its been wearing the seal in front of the thicker part of the shaft. I don't have the same wear marks on the OEM...
Yes, new spindles with new brass bushings.
Was gonna try putting the old axles back in and see if I have any issues. Would really hate to find out that the rcvs were bad from the get go. I’m sure it’s been too long to get them to replace them if that was the issue.
Yeah, not gonna use the marlins.
Housing is fine. No issues till I did the first knuckle job. I don’t wheel it hard at all. Mostly desert trips.
Breather is clear. I blew air through it when the seal was out.
Oem seals. Sumos this time. Used Toyotas last time. Full time fwd. Overfilled may be possible., but doubt it. Gonna try adjusting the axle alignment. Got a buddy with the sst. Seems strange to me that such thin shims matter so much when the axle seals have some flex.