Archived 2005 3500 repeated front axle seal leaking

[mweiman]

Anyone ever run across this issue before? I have a customer that recently bought a 2005 3500 4x4 with about 240,000 miles on it to transport RV's. Shortly after he bought it the left front axle seal started leaking bad. I disassembled front axle and replaced both seals with parts from Dodge dealer. The left seal was coming apart and obviously bad. Everything went back together good. Shortly after they both were leaking again, the left worse that the right but both leaked. Disassembled and replaced again with tool and seal kit from Quad 4x4. Checked everything over extra good and forced seals in farther to where they would bottom in the axle tube. Axle shafts have no groove still have the machine marks on them. Left leaked again, I tried pulling the axle shaft and applying rtv to it to seal the shaft to the rubber ring of the seal, just to try something quick and filled with lucas oil instead of the 75w-90 that I had been using. After 2 weeks it is leaking again and he said the right is seeping some also. I also have been leaving the oil level about 1/2 inch below the fill hole. I was wondering if the spider gears are somehow too loose and moving the axle shafts around enough to damage the seals or make them wick oil out. I am going to pull the front cover on my 03 to compare how tight they are. Anyone have any other thoughts or ever experience this? Don't know any truck history for sure but no signs that the axle has been hit, the ball joints and u-joints are tight. Truck appears fairly clean other than some rust. It fairly recently had a right wheel hub bearing and front brake pads that I can tell. Only other thing is the dust shields on the brakes are rusted and have been removed.
Thanks for any ideas,
Matt

 

[mwilson]

See if the vent line is clear. Pressure builds up as the vehicle is driven and forces gear oil out around seals if the unit can't breathe.

 

[Joseph Donnelly]

I put a film of moly camshaft lube on the seal lip and the axle shaft in that area to help break in without burning up the seal. Also check that the housing is not bent.

 

[AEdelheit]

I would also make sure the axle housing is not bent as that can cause the seals to wear quickly and the axles are pretty easy to bend.

 

[mweiman]

I have checked the vent is clear and I lubed the axle shafts putting them in. Can't remember for sure but I was thinking there was some movement up and down in the side gears of the differential. I am going to pull the front cover of my 03 to compare it. And see if I can get him into an alignment shop to get checked for axle being straight.
Matt

 

[Bob4x4]

When installing the axels it is usually easy to if the housing is bent. If you can't tell that way stand 50 feet in front of the truck and look for camber The FSM gives good instructions on setting the bearing preload and gear contact

 

[mweiman]

I got the front cover pulled on the differential this afternoon and there was a good 1/8 of movement up and down I could get on the side gears of the differential. That seems like it would allow the shaft to move around enough to make the seals leak. I don't see any type of bushing on the diagram of the differential so I am thinking that the center housing is worn. Working on finding a new center section, I checked with Torque King and their customer service was great, but it was going to be a week or better before they could get one to me so I am trying to find one quicker.
Matt