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I would second Roger’s suggestion and put it in with a bit of sealant or Loctite, a 0.4mm recess is not going to hold it in.
Still a bit of a mystery why the casting is larger than it should be, I wouldn’t have thought that even if the oil seal spun round it would wear the casting, perhaps yours was made on a Friday afternoon.
2020 blue SZ5 (one of the last to be registered in the UK)
Ex 2011 Blue Jimny SZ4
Northumberland Jimny Blog
I think the casting is slightly larger initially from memory as the seal is very easy to push into the recess. It's only the last few mm that pinch up and hold it in place, but this requires driving home with an oversized socket to avoid damaging it. So once driven full home it is quite tight and will not easily move. But as said if you have any doubt a bit of sealant will not hurt anything, but it should not be needed.
Yokohama Geolanders, Sony head unit, NAUTILUS Air Horn, DRL conversion, Rear cargo space, Elvis Bobblehead, transfer Guard, Indian hanging Elephant, Koni Heavy track dampers, Custom SS exhaust, Voodoo Doll, Adventure Rack with LED ight bar, vintage ERIBA caravan usually attached (yes it's slow)
It's leaking again! Really don't know what to do with it. That's 3 new seals and each one has come out.
A wild thought - is it possible the diff breather is blocked and pressure is pushing out the seal when it warms up? Does the breather just pull off to check?
Otherwise I am looking for something to stick the seal in place. Can't find agreement on what would stick it. I have seen Loctite green mentioned, Loctite 603, Permatex 2B.
Unfortunately the front axle is inert in normal 2wd drive mode so doesn't create that kind of heat. To me it's starting to sound like something has happened/been done to damage the seal seat at some point in the past. The option is probably going to be either have the seat remachined to the next nominally sized seal or replace the whole axle case with a known good one. Not cheap either way. If it's any consolation I am having the same issue with one of the kingpin bearing seats and all the clever loctite compounds are at best a sticking plaster on a gunshot wound.
Temeraire (2018 quasar grey automatic)
One of the last 200ish of the gen3s, probably.
ADOS Attention Deficit Ooooh Shiny!
Thank you for the advice. As this is a vacuum hub version surely the diff and shafts are active when driving? 4WD is engaged when the hubs are locked into the shafts.
I can't imagine anything sticking the seal in though.
Tempted to bite the bullet and take it to the Suzuki dealer to get them to fit a seal.
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