I'm kind of at a loss on this one. I've had the drivers side front axle seal replaced on my wife's van by my mechanic. It was leaking pretty good. After getting the car home it started leaking again. Took it back and they put in a new seal. Both seals came from ford dealer. Car didn't leak for two weeks. Now car leaks after about two hours after you shut it off. Sometimes it doesn't leak at all. Its an intermittent prob but getting very annoying.
Anyone have any ideas? Thanks!! :confused:

What you need to do is get rid of the van! I had the same van, it was always breaking down and it costed my thousands of dollars to fix and it finally broke down completely last year. During the times I had to call for towing. The tow truck drivers always told me, "windstars are no good." Sorry!

Here's how it's normally done:

. Pry seal and metal protector from transaxle case with a large screwdriver or prybar.

. Tap new seal into case with a seal driver or large socket, with an outside diameter slightly smaller than that of the seal, and a hammer. Ensure seal is square and seated in the bore (be careful not to cock the seal in the bore). Then, use a seal driver to install a new metal cover over the seal (make sure this was done).

. Reinstall driveaxle, wheels and lug nuts. Lower vehicle and tighten driveaxle/hub nut to proper torque (make sure this was done).

Many mechanics only use air tools these days and don't torque fasteners properly. Accordingly, they tend to be over or under torqued. This should have been a straight-forward and uneventful repair. Since it's a Ford, I would take it to Ford for servicing, especially for anything major.