Replace the front axle shaft seal on the driver or passenger side to stop differential fluid leaks at the axle housing.

Warnings

Tools required

Parts

• Front axle shaft seal × 1 — Use OEM specification
• Axle nut cotter pin or staking kit × 1 — Match axle nut retention method
• RTV silicone sealant (if seal requires) × 1 — Use OEM specification

Fluids

• 75W-90 GL-5 Gear Oil — 1.5 qt

Preparation

1. Park vehicle on level, solid surface and engage parking brake
2. Chock rear wheels securely
3. Allow differential to cool completely if recently driven
4. Verify replacement seal matches original (inside diameter and outside diameter)
5. Place drain pan under front differential

Procedure

1. 1

   Remove wheel and tire
   Loosen lug nuts while vehicle is on ground. Raise front of vehicle and support securely on jack stands at frame contact points. Remove lug nuts and wheel/tire assembly.
2. 2

   Remove axle nut retention
   Remove cotter pin from axle nut using side cutters or pliers, or if staked, use chisel to unstake the nut collar. Discard cotter pin or staking material as it cannot be reused.
3. 3

   Remove axle nut
   Use 36mm socket and breaker bar to remove the axle nut. Have assistant apply brakes or use pry bar between lug studs to prevent rotation. Support the outer end of the axle shaft as it may shift outward when nut is removed.
   ⚠Axle nut is under high torque - ensure socket is fully seated to prevent rounding
4. 4

   Disconnect CV joint from axle shaft
   Locate the six CV joint bolts connecting the inner CV joint to the front axle shaft stub. Remove all six bolts and separate the CV joint from the stub shaft. Wire the halfshaft assembly to the suspension or frame to prevent damage to the outer CV boot.
   Torque spec

   CV Bolts76 Nm (56 lb-ft)
5. 5

   Remove axle shaft from differential
   Pull the axle shaft stub straight out of the differential housing. Some gear oil will drain from the housing opening. Allow fluid to drain into pan. Inspect shaft splines for damage or excessive wear.
6. 6

   Remove old seal
   Using slide hammer with seal puller attachment, hook the inner lip of the axle seal and extract it from the differential housing bore. Alternatively, carefully pry out the old seal using appropriate tools, being careful not to damage the housing bore surface.
   ⚠Do not gouge or scratch the seal bore in the housing - damage will cause new seal to leak
7. 7

   Clean seal bore
   Thoroughly clean the seal bore in the differential housing using wire brush and brake cleaner. Remove all old seal material, dirt, and debris. Inspect bore for damage, gouges, or corrosion that could prevent proper seal seating. Wipe clean with shop rag.
8. 8

   Install new seal
   Lightly coat outer diameter of new seal with gear oil. If seal manufacturer specifies, apply thin bead of RTV to outer edge. Position seal squarely in bore with spring side facing inward (toward differential). Using seal driver or appropriately sized socket, drive seal evenly into bore until fully seated and flush with housing face.
   ⚠Seal must be driven in straight - cocking the seal will damage it and cause leaks
9. 9

   Lubricate seal lip
   Apply fresh 75W-90 GL-5 gear oil to the inner lip of the new seal where it will contact the axle shaft. This prevents dry start damage during initial operation.
10. 10

    Reinstall axle shaft
    Carefully guide the axle shaft stub into the differential housing, through the new seal, and into the differential side gear splines. Push firmly until shaft is fully seated and engages the side gear. Rotate shaft slightly if needed to align splines.
    ⚠Be careful not to cut seal lip on shaft splines during installation
11. 11

    Connect CV joint to axle shaft
    Align the inner CV joint with the axle shaft stub flange. Install all six CV bolts finger tight, then torque in a crisscross pattern to specification.
    Torque spec

    CV Bolts76 Nm (56 lb-ft)
12. 12

    Install axle nut
    Install new axle nut onto the outer end of the halfshaft. Torque to specification while preventing rotation using the brake pedal or pry bar method. Install new cotter pin through nut and castle slots, bending ends to secure, or stake nut per manufacturer method.
    ⚠Cotter pin or staking is critical to prevent nut loosening - do not reuse old hardware
    Torque spec

    Axle Nut250 Nm (184 lb-ft)
13. 13

    Refill differential
    Locate the differential fill plug on the front differential housing. Remove fill plug and add 75W-90 GL-5 gear oil until it reaches the bottom of the fill hole (fluid should just begin to seep out). Install and tighten fill plug. Verify vehicle is level during this process.
14. 14

    Reinstall wheel
    Install wheel and tire assembly onto hub. Thread lug nuts by hand, then lower vehicle until tire contacts ground. Torque lug nuts in star pattern to specification. Lower vehicle completely and remove jack stands.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Torque all fasteners in the sequence specified in the procedure steps
2. Ensure new cotter pin is properly installed and bent to secure axle nut
3. Verify differential is filled to proper level with correct fluid specification

Verification

• Start engine and turn steering wheel lock to lock several times to circulate fluid and check for leaks at seal
• Test drive vehicle for 5-10 miles and recheck differential fluid level
• Inspect axle seal area for any signs of leakage after test drive
• Verify no unusual noises from front differential or CV joints during operation
• Recheck axle nut retention (cotter pin or staking) is secure

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