Hey everyone, My 89 GTI 16v with 155K was leaking at the passenger side drive flange seal. The drive flange itself had alot of play, so I ordered a new one along with a seal kit.
I tore it apart and reinstalled everything and the thing was leaking after a 5 mile drive! I thought I did everything right - I packed the backside of the seal with grease to help retain the spring per the Bentley manual, and used a pusher made from a round piece of metal, a bolt, and a nut to push the seal in until it was seated. I also used a pusher like the VW tool to press the flange onto the shaft. It looks like the gear oil is leaking between the flange and the seal. My guess is that maybe the spring popped out of the seal when the flange was being pressed on? Or maybe the seal isn't completely seated? I did munge the green sleeve a bit when removing the seal, but only at the outside edge, and it doesn't look like anything is leaking there. Any ideas what I could have done wrong? Thanks -Ken sick '89 GTI 16v
