Civic Axle Shaft Replacement Nightmare

This has been the most frustrating of the many car repairs that I've done
over the years. I've replaced the passenger side drive axle on my '90 Civic
four times and apparently I'm not done yet. The first three were ARI brand
reman shafts which either were noisy or vibrated. Finally, I had the parts
store order me an A-1 Cardone axle and I thought my problems were solved.
But, now I've found that the seal is leaking. When I installed the axle I
noticed it was considerably harder to insert into the transmission than the
others but I was thinking the circlip in the end that retains it in the
trans was hanging up. Now, I'm thinking they gave me the wrong shaft (yes I
know how that sounds) that did not fit the seal correctly. Does anyone know
if there are differences in the shafts for Civics, such as having a larger
diameter where the seal fits? I noticed the Cardone axle was different from
the others where the big nut is staked. It had a flat spot to flatten the
nut against rather than a keyway. I thought this was strange but I know
that Honda frequently makes production run changes. Does anyone out there
have a clue to what the problem might be? Wrong shaft? Bad mechanic?
Phase of the moon wrong?

BTW, this is an indie parts store that has an excellent local rep, but I'm
frustrated beyond belief with them now.

Thanks for any help,
WW

 

After being replaced 4 times, I think that it is more likely that the seal
is just worn out or damaged.

 

The seal could be damaged, but on my 87 prelude,
there are like 3 different sizes of shaft, i
found that out while trying to find a new seal.
and they are cheap, like $10 a side, so you
might as well get them.

t

 

there's different overall diameters - not sure if there's any
differences specific to the seal. chances are, as stated by the others,
it's a damaged seal. just replace it & you'll be fine.

don't worry about it - still works the same.