There is a special type of welding that sprays hot metal onto a spinning shaft or axle to build it up and then after cooling the shaft or axle is machined back to its proper size. I don't know if it is available where you are or if it is cost effective.
I had a rear axle on a Jeep cherokee xj that kept leaking even though I kept having new seals put in (not nearly as bad a leak as yours). I finally gave up on it and presumed that the axle housing was bent. I got another used complete axle and that fixed my problem.
On your axle I am wondering if the seal is fitting into the axle housing properly. You can pull the axle shaft, then try tapping a seal into the housing without the shaft. If it fits tight, then remove that seal and you have eliminated another variable for the cost of a seal.
Also, make sure that the retaining plate is on correctly. I believe that there may be a raised bit on one side of the plate that is supposed to push the seal into the housing, that raised bit should be touching the seal if the plate is installed correctly.
Lastly, the bearing retaining ring is removed by drilling a hole through it, but not deep enough to drill into the shaft. Then use a cold chisel to split the ring, again, don't damage the shaft. It may be possible to pull the bearing at that point without cutting it if you have a large enough shop press.
Dave
I had a rear axle on a Jeep cherokee xj that kept leaking even though I kept having new seals put in (not nearly as bad a leak as yours). I finally gave up on it and presumed that the axle housing was bent. I got another used complete axle and that fixed my problem.
On your axle I am wondering if the seal is fitting into the axle housing properly. You can pull the axle shaft, then try tapping a seal into the housing without the shaft. If it fits tight, then remove that seal and you have eliminated another variable for the cost of a seal.
Also, make sure that the retaining plate is on correctly. I believe that there may be a raised bit on one side of the plate that is supposed to push the seal into the housing, that raised bit should be touching the seal if the plate is installed correctly.
Lastly, the bearing retaining ring is removed by drilling a hole through it, but not deep enough to drill into the shaft. Then use a cold chisel to split the ring, again, don't damage the shaft. It may be possible to pull the bearing at that point without cutting it if you have a large enough shop press.
Dave
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