Is my tranny or differential broke? Options

[HardHead93]

The car has been leaking gear oil. I thought it was an axle seal so I took it to my local shop because they installed the original seal and would warranty it. Come to find out it is not the seal. The axle has some serious in and out play in it. When it moves out gear oil leaks out. The shop has tried 2 other brand new axles and the problem is the same. The last axle would not click and lock in. I have a helical LSD in an S54 transmission and I am running a Gen 4 3sgte tuned for 340 hp on E85. I track the car so it gets beat on pretty hard. The shop is having a hard time getting a good part number because the original part number is discontinued but superseded by another. One axle came from OReilly's and the other came from AutoZone. Is the tranny or the differential broke or am I not getting the right axle? Has anyone else had this problem?

[slavie]

Can you quantify "serious in and out play"? Also, I'm assuming we're talking driver's side axle since you mentioned the snap ring which is not present in the pas side axle.

Some in and out play is normal as there's some slop in the snap ring securing mechanism. Maybe about 1/8 of an inch.

With aftermarket axles, you MUST install a new seal with a new axle. OEM seal is much preferred - I've had aftermarket seals leak within weeks of installation. As you may have heard, quality control on aftermarket garbage is non-existent, and sometimes the shaft is slightly undersized. A new seal will wear to the shaft, if you will, and seal. If you then take a new, random-sized shaft, and the old seal that was previously working on a different sized shaft, you get a pretty massive oil leak - you'd be surprised just how much oil can leak past. We're talking puddles, not just stains under the car. Ask me how I know.

The fact that a third axle would not even snap in does not surprise me either. I've had aftermarket axles where the snap ring it would seem was bent out of some standard wire not treated in any way with no spring to it, and that garbage will deform and not go in when you try to insert it. I've had to remove original springy snap rings and put them onto brand new aftermarket axles.

TL;DR: Aftermarket garbage is the root of all evil and belongs in the garbage.

[HardHead93]

Can you quantify "serious in and out play"? Also, I'm assuming we're talking driver's side axle since you mentioned the snap ring which is not present in the pas side axle.

Some in and out play is normal as there's some slop in the snap ring securing mechanism. Maybe about 1/8 of an inch.

With aftermarket axles, you MUST install a new seal with a new axle. OEM seal is much preferred - I've had aftermarket seals leak within weeks of installation. As you may have heard, quality control on aftermarket garbage is non-existent, and sometimes the shaft is slightly undersized. A new seal will wear to the shaft, if you will, and seal. If you then take a new, random-sized shaft, and the old seal that was previously working on a different sized shaft, you get a pretty massive oil leak - you'd be surprised just how much oil can leak past. We're talking puddles, not just stains under the car. Ask me how I know.

The fact that a third axle would not even snap in does not surprise me either. I've had aftermarket axles where the snap ring it would seem was bent out of some standard wire not treated in any way with no spring to it, and that garbage will deform and not go in when you try to insert it. I've had to remove original springy snap rings and put them onto brand new aftermarket axles.

TL;DR: Aftermarket garbage is the root of all evil and belongs in the garbage.

As far as shaft play I would say it is around 1/8 - 1/4" in and out play. The seal does not leak when it is on but leaks a bunch when it is out. I wish I would have taken a picture but yes the snap ring looks like a bent piece of wire. The mechanic was able to widen it with some pliers. The axle never unsnaps just has a lot of play. After all your guys input I think the snap ring is too thin and is cheap garbage.

I want to say the manual and auto use a different axle and that the length of the part that inserts into the trans is the difference, with one being longer or shorter than the other. I'm assuming it's the driver side because they're the same auto or manual on the right side it seems.
Automatic
https://www.rockauto.com/info/570/TO-8145__ra_p.jpg

Manual
https://www.rockauto.com/info/570/TO-8106__ra_p.jpg

What often happens is that cores aren't sorted/boxed right when they go back for refurb so you'll get parts randomly boxed wrong that way. Might be worth checking inside the diff with a flashlight to make sure nothing has gone wrong, how did the old axle that came out look? Is there excessive up down play in the bushing the axle rides on?

When I look at your picture of your axle, I see one major difference from mine, it does not have the dust shield over the axle seal. Every OEM picture I see of an axle has that dust shield. I wonder if they went to some cheap replica because like I said earlier, the part number been superseded by a different one.

^That. My brother had issues with his Maxima and more recently his Audi with CV axles and seals. Honestly I'd find a good used o.e. axle and refurbish it if possible, and use a new o.e. seal. That or use this as an excuse for custom higher strength axles.

I order an OEM seal. What do you mean my custom high strength axles?