Well , I finally did it. Took me about 12 hrs. And now I have a leak. So help me figure out what went wrong.
Looks like the seal/bushing were replaced before, because I saw some nicks here and there on the housing.
Here are my recollections that could have caused the screwup.
a) Does the seal go all the way in, or should be flush with the top metal surface? I had it flush with the metal surface. I could have pushed it in deeper all the way until it stops.
b) I pressed the bushing in, but the socket I used was a little small, so upon pressing, it skewed and screwed up the edge of the bushing. I filed it to smoothen it out. I also used sandpaper to smoothen the inside surface of the bushing a little. Maybe I should not have done this. I ended up continuing with a bigger socket and the bushing went in fine.
c) When I removed the flange bolt to get the housing out, the flange slid out easily over the splines. It was NOT the same when I put everything back together. I had it hammer it in with a piece of wood after the falange went in a little. Could it be the new bushing, and is this normal, or should it slide in effortlessly ?
d) I cleaned the gasket surface very well, used fine sandpaper, no traces of gasket left. Maybe I screwed it up putting the gasket back on when I was tighting the ext housing. I doubt it thugh.
e) I get the leak only when I am driving ... a streak of oil is left behind tracing the car's path.


So I am going to order the parts again, and do this damn job again and I need inputs from you guys.

Thaanks a bunch
zakir