Daniel...is there a bunch of movement up & down & around that might
indicate the bearing behind the seal is bad and causing the flange to
move more than the seal will handle??? I put the seals in so they are
flush with the housing, but being driven in all the way is OK also...not
critical if things are not flopping around a bunch. I use only VW factory
seals and have only had 1 leak ever...never figured out why that one did
it.
 if all else seems Ok, then try another seal and see if you just buggered
up the other one on install and keep an eye on it. Call me if you have
any questions

Daryl of AA Transaxle
Duvall, WA. (Seattle area)
(425) 788-4070
1-877-377-0773 (toll free)
aatransaxle.com (web site)

rom:    "Daniel E. Dedrick" <dan_dedrick@YAHOO.COM>
Subject: Syncro Tranny

Hi all -

The front drive output seal on my 4WD tranny started
leaking so I replaced it a few months ago. Having
never worked on this tran-axle before, I packed the
seal with grease and tapped it in with a mallet and
large socket as if it were a differential seal.

Everything went well, in fact maybe to well; it tapped
in quite easily. The Bently manual instructed me to
"drive in to stop". I was not sure if this meant to
drive the seal in until it rested against the bearing
or if the special tool placed the seal at a
unspecified depth. Anyway, long story short, I tapped
in the seal until the seal rested against the bearing.

All seemed to work out fine until this weekend, with
approximately 2000 mi on the new seal, it started
leaking again only this time worse. Does anyone have
any input on this?

Thanks for listening - Danie