• Welcome Visitor! Please take a few seconds and Register for our forum. Even if you don't want to post, you can still 'Like' and react to posts.

leaking out of axle tube on Dana 44


Hagan

08/2013 OTOTM Winner
V8 Engine Swap
OTOTM Winner
Solid Axle Swap
Joined
Jan 3, 2009
Messages
1,079
Reaction score
11
Points
0
Location
Salem, OR
Vehicle Year
1986
Make / Model
Ford
Engine Size
2.3
Transmission
Manual
So I'm almost finished with my SAS. I flexed my truck out on some tires yesterday to measure for shocks and I didn't notice it but I saw gear oil on the ground on the left side (the side pointed towards the ground) and I flexed it out again today and I saw it leaking out of that side while flexed. It has new seals everywhere including the differential seals. I removed the axle shafts 1 and installed them twice and I could feel the seal. So, is this normal for this to happen? Its not like its going to be flexed out all the time.
 


93 4x4

Member
Solid Axle Swap
Joined
Nov 29, 2009
Messages
223
Reaction score
1
Points
18
Location
florida
Vehicle Year
1993
Make / Model
Ford
Engine Size
4.0
Transmission
Manual
no that's not normal, are you sure you didn't tear the seal
 

Sasquatch_Ryda

Well-Known Member
Ford Technician
OTOTM Winner
Solid Axle Swap
Forum Staff - Retired
TRS Banner 2012-2015
Joined
Aug 8, 2007
Messages
7,916
Reaction score
108
Points
63
Age
36
Location
Terrace, BC, Canada
Vehicle Year
1991
Make / Model
Ford
Engine Type
4.0 V6
Engine Size
4.0L
Transmission
Automatic
2WD / 4WD
Solid Axle Swap 4x4
Tire Size
40s
You previously pulled the shafts out? Some fluid might have spilled over the seal when the shaft was removed and remained in the tube to slowly leak out. Other than that, the seal is pooched.
 

Hagan

08/2013 OTOTM Winner
V8 Engine Swap
OTOTM Winner
Solid Axle Swap
Joined
Jan 3, 2009
Messages
1,079
Reaction score
11
Points
0
Location
Salem, OR
Vehicle Year
1986
Make / Model
Ford
Engine Size
2.3
Transmission
Manual
You previously pulled the shafts out? Some fluid might have spilled over the seal when the shaft was removed and remained in the tube to slowly leak out. Other than that, the seal is pooched.
Yeah but it was dry then. The seals are meant for easy installation of the axle shafts. They slid in very nicely and without a fight. I didn't jam the axle shafts into the housing I held them up and slid them in.

There is so much work involved to get to that stupid seal. Honestly I think I've had to buy 2 of every seal and every bearing to put this together. I am very frustrated.
 

Dugan

Member
Joined
Apr 5, 2012
Messages
646
Reaction score
12
Points
18
Location
New Castle, DE
Vehicle Year
1989, 1949
Make / Model
Ford, IH
Engine Size
2.9L, 355 SBC
Transmission
Manual
May sound dumb, but how securely did those axle seals fit? I had a d44 once that had a special seal instead of the normal look it up yourself at autozone seal. It was PN 2300 ill never forget it and they are 25$ a piece.
 

cdawall

New Member
U.S. Military - Active
Solid Axle Swap
Joined
Jan 29, 2010
Messages
549
Reaction score
5
Points
0
Location
Ellsworth AFB
Vehicle Year
2005
Make / Model
Ford
Engine Size
4.0L V6
Transmission
Automatic
Did you overfill the pumpkin that will do it as well.
 

legoms013

09/2013 OTOTM
Article Contributor
OTOTM Winner
Solid Axle Swap
Joined
Apr 7, 2008
Messages
2,629
Reaction score
26
Points
0
Location
CA
Vehicle Year
1996
Make / Model
Ford Ranger
Engine Size
4.0L V6
Transmission
Automatic
You previously pulled the shafts out? Some fluid might have spilled over the seal when the shaft was removed and remained in the tube to slowly leak out. Other than that, the seal is pooched.
This eleventy billion ^
 

Ford78

December 2012 OTOTM
V8 Engine Swap
OTOTM Winner
Solid Axle Swap
Joined
Jun 12, 2011
Messages
752
Reaction score
3
Points
18
Location
Iowa
Vehicle Year
1999
Make / Model
Ford
Engine Size
351w
Transmission
Manual
At least u tried to put new seals in, I put everything new on my dana 44 and forgot about the seals and guess what= their leaking. just whaen u think it ready to go something always pops up.
 

Hagan

08/2013 OTOTM Winner
V8 Engine Swap
OTOTM Winner
Solid Axle Swap
Joined
Jan 3, 2009
Messages
1,079
Reaction score
11
Points
0
Location
Salem, OR
Vehicle Year
1986
Make / Model
Ford
Engine Size
2.3
Transmission
Manual
Ok so I pulled everything off to find out the seal was good. I did tear the rubber at the very edge removing it (I used a piece of pipe and rubber mallet) but the seal looks perfect. I did paint the axle shafts and I'm thinking maybe I painted it in a bad spot? I don't know. I really don't want to replace this seal and have it leak again. I filled it until it was coming out of the fill plug. It leaked all over my tire and the shaft was soaked in gear oil (just on the bottom). I'm going to get a new seal and pop it in.
 

Hagan

08/2013 OTOTM Winner
V8 Engine Swap
OTOTM Winner
Solid Axle Swap
Joined
Jan 3, 2009
Messages
1,079
Reaction score
11
Points
0
Location
Salem, OR
Vehicle Year
1986
Make / Model
Ford
Engine Size
2.3
Transmission
Manual
So just to make sure you fill the dana 44 up until it comes out of the fill plug correct?
 

Sasquatch_Ryda

Well-Known Member
Ford Technician
OTOTM Winner
Solid Axle Swap
Forum Staff - Retired
TRS Banner 2012-2015
Joined
Aug 8, 2007
Messages
7,916
Reaction score
108
Points
63
Age
36
Location
Terrace, BC, Canada
Vehicle Year
1991
Make / Model
Ford
Engine Type
4.0 V6
Engine Size
4.0L
Transmission
Automatic
2WD / 4WD
Solid Axle Swap 4x4
Tire Size
40s
Yes. You might have gotten paint on the sealing surface of the shaft? Should be a nice smooth polished surface.
 

cdawall

New Member
U.S. Military - Active
Solid Axle Swap
Joined
Jan 29, 2010
Messages
549
Reaction score
5
Points
0
Location
Ellsworth AFB
Vehicle Year
2005
Make / Model
Ford
Engine Size
4.0L V6
Transmission
Automatic
So just to make sure you fill the dana 44 up until it comes out of the fill plug correct?
If you have a stock cover yes. If its an aftermarket cover it depends.
 

Hagan

08/2013 OTOTM Winner
V8 Engine Swap
OTOTM Winner
Solid Axle Swap
Joined
Jan 3, 2009
Messages
1,079
Reaction score
11
Points
0
Location
Salem, OR
Vehicle Year
1986
Make / Model
Ford
Engine Size
2.3
Transmission
Manual
Well its all back together. Its flexed out and I'm going to leave it there for a little while. I realize there is some differential fluid stuck in the axle housing but I should be able to tell by how much comes out whether its the seal or just some left over fluid
 
Last edited:

Sponsored Ad


Sponsored Ad

Staff online

Member & Vendor Upgrades

For a small yearly donation, you can support this forum and receive a 'Supporting Member' banner, or become a 'Supporting Vendor' and promote your products here. Click the banner to find out how.

Truck of The Month


Kirby N.
March Truck of The Month

Recently Featured

Want to see your truck here? Share your photos and details in the forum.

Follow TRS On Instagram

TRS Events

25th Anniversary Sponsors

Check Out The TRS Store


Sponsored Ad


Sponsored Ad

Sponsored Ad


Amazon Deals

Top