leaking out of axle tube on Dana 44

[Hagan]

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]

no that's not normal, are you sure you didn't tear the seal

 

[Sasquatch_Ryda]

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]

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]

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]

Did you overfill the pumpkin that will do it as well.

 

[legoms013]

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]

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]

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]

So just to make sure you fill the dana 44 up until it comes out of the fill plug correct?

 

[Sasquatch_Ryda]

Yes. You might have gotten paint on the sealing surface of the shaft? Should be a nice smooth polished surface.

 

[cdawall]

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]

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