SW20 turbo gearbox leaking - help!

[Wildcard]

So I have just finished my turbo swap into my NA and now the turbo gearbox is leaking fluid from the drivers side axel - I noticed this after about 150km.

Now, the facts at hand:
1) This was the side of the Taupo accident, although none of the suspension was damaged in a way that would suggest to me the gearbox took an impact
2) Before putting the engine back in we replaced the gearbox-axel seals as a precaution
3) The drivers side axel assembly has about 4mm of play in it [in-out of the box] and the passengers side about 6mm - I don't know why? There is no obvious knocking when driving however.
4) The box drives fine
5) On the turbo axels I have, the part of the axel that goes into the box and the spline was quite rusty. I spent quite a bit of time cleaning this up but the smooth part of the axel that goes inside the box still has a small amount of pitting that seemed 'impossible' to remove. I figure its a possibility that these tiny pits have warn away the rubber gearbox seal - but in 150km???

Here's a pic... any ideas here would be great.

[Mr Revhead]

if the axle is pitted the seal maynot be able to seal against it...

also how much oil was put in?

ps. good to see it back on the road

[fivebob]

Depending on how bad the pitting is you may have to replace the axle, however In my experience it would have to be pretty bad for it to leak.

More likely is that you damaged the seal when installing it or the axles or got a bit of grit trapped between the seal and the axle. I know it's too late now, but my preferred option is such cases is to only replace such items if they leak, just in case usually leads to these sorts of problems.

[deaf_rattle]

its mikes fault

[anthonym]

I can't really add much to what others have said except that I've had many simlar leaks on various MR2 turbos, generally attributable to leaking seals. If it's only a tiny leak, like a couple of drips on the floor after the car has been standing for a week, then it's an annoyance but not worth the hassle to fix IMO. I've driven around for months/years with similar and worse leaks without any problem and no discernable decrease in gearbox oil level.

[Wildcard]

Thanks, it was a few drops after a nights sitting - the possibility of it getting worse and running out of fluid doesn't sit well with me but I think as you suggest I'll just keep an eye on it for the moment.

Fivebob / Nemesis, can you confirm the play in the driveshafts going into the box is 'normal' ?

[fivebob]

Fivebob / Nemesis, can you confirm the play in the driveshafts going into the box is 'normal' ?

IMO the amount of end float you describe is nothing to worry about, I haven't measured mine but I'd guesstimate it's around 3-4mm. On the drivers side it's pretty much determined but the amount of movement in the support bearing that's attached to the motor, on the passengers side the CV joint is where most of it comes from. There is little if any axial load on diff outputs so it's no as though it's going to hammer itself to death.

[Wildcard]

Thanks for explaining that, I shall just keep an eye on it for the moment....

[Tranquil]

Had to replace the drivers side axle seal on my gen3. Awoke to a large smelly puddle of Redline