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Did you inspect the bushing inside, just behind the seal? On the 6F35, when it originally was introduced, they had problems with the seals. Apparently it was a problem with the bushing.
You can attempt to shake the axle close to the seal to determine its fit into the bushing. If you can move it around, either the axle diameter is too small, or the bushing is worn. It should have very minor play.
Did you happen to check the fit of the seal on the axle surface? If it was loose when you first install it, it likely won't seal to well. I cannot describe very well, but the seal should wipe the mating surface of the axle, not slide loosely. But not be grabby. A minimal force on a lightly lubed surface, but not so loose fluid can leak past. Oy.
Anyway, give the axle a shake near the side of the case, and if it moves, check the other, non-leaking (I assume) side for comparison.
If the bushing is bad, you may want to watch a youtube about cutting the bushing and worming it out of the case without having to drop the transmission. Makuloco may have done one on a 6F35, or not. Either way the procedure should be about the same, I think.
tom
 

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When you put the axle into the transmission, does it wiggle freely, or does it seem firmly held in place with little movement?

You have the basic idea right on the money. Press/tap it into position in the side case, and re-insert the axle.

The shaft of the axle, the machined part that is/should be shiny, that stuffs into the transmission should ride on a bushing which is a cylinder in the diameter of the axle shaft, with varying length, depending on design. Most times the bushing will be brass, and around the circumference of the axle shaft. It surrounds the spline and axle(when installed) and keeps the axle aligned and centered.
If Ford did not use a bushing, then the axle would ride on the metal of the case, aluminum, but would still need to be held in place or you might get leakage and vibration. Does it wiggle? If not, replacing the seal should do the trick. If the axle surface has a groove worn into it, then you may get leakage from that if you align the groove with the lip of the seal. In that case you may want to drive the seal in slightly short of the original spot, or deeper, to avoid the lip being astride the groove.
tom
 
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