Leaking front differential

So I recently changed (filled) the front differential (Dana 27) oil and now I have a leak, about an ounce or two a day. Best I can tell it's coming from the aft end where the drive shaft is.

When I drained it first water then a sludge came out, no oil. I cleaned it all out, the gears looked ok and I filled it with GL5. No leak at the gasket/cover on the front, but the oil trail leads back and up to the pinion seal (if I have my terms right).

Is this a hard fix? Do I need to simply replace the pinion seal (this thing)? http://walcks4wd.shopgate.com/item/383339

Regards,
Tim

 

Another thing to keep in mind - if the differential was full of sludge, the outer pinon bearing is the first to be deprived of lubrication. The seal could be leaking because the outer pinion bearing is failing.

IIRC you are supposed to use a new nut on the pinion when you replace the seal. The seal is a parts store item - no need to get one from a Jeep retailer. http://www.rockauto.com/catalog/moreinfo.php?pk=1835570&cc=1309418&jnid=460&jpid=0 Jeep PN 639265

 

"Sleeve"? Is that something readily available at a tractor supply or auto parts store? sorry for being thick.

Regards,
Tim

 

So I should look for a new nut as well? And bearings as I don't want to tear into it and find I need one.

Regards,
Tim

 

Usually called a "Speedi Sleeve" - a decent parts store can get one. It slips over the yoke, and you need a special seal to go with it. But don't burn that bridge until you come to it. It may be cheaper/easier/simpler to just replace the yoke if it has a groove worn in it.

I would use a new nut if I could get one.

 

I'll get the nut as well, thanks.

Regards,
Tim

 

here is the sleeve
http://www.monstertransmission.com/...-30-Dana-44-Dana-50-_p_9290.html#.VeOXqov4ulI
but if you have a 10 spline pinion gear the yoke here is under 50 bucks
http://www.cj-jeep.com/cj5-6/cj5-6frontaxleparts.htm
no special seal required.

 

Wow, that is a difference! Thanks for the info.

Regards,
Tim

 

If you use a quality seal like a National no special seal is needed with a repair (Speedi) sleeve. A good seal is flexible enough to take up the extra thickness. A new nut is a good idea as is filling the groove with an epoxy so the repair sleeve doesn't collapse into the groove. Red thread locker is also a good idea on the sleeve when installing. It acts like a lubricant for easier installation, acts as a sealer, and keeps the sleeve from coming loose down the road.

 

I ordered both inner and outer seals and the nut. When they arrive I'll dive in and hope no other damage exists.

Regards,
Tim

 

Inner seal?

 

Good question. There is only an outer pinion seal...

 

Walck's listed both an inner oil slinger and an outer oil slinger, plus the outer seal. In looking at the diagram in the FSM it shows this plus inner & outer bearings and cups and the shims. Since they weren't expensive, I got them.

Regards,
Tim

 

Inner oil slinger lives on pinion between bearing. The outer slinger should be fine. To replace the bearings you will need to remove the case. you don't want to do that. Replace the seal and instal new yoke or sleeve if required.