2003 Sahara rear axle leak

[gijoejw]

I have an 03 Sahara and everything is great with it, got it about a month ago. I knew when I bought it, it had a leaking left rear axle seal. Bout the only issue. So I took it to the shop I use and when they took the axle shaft out, it was new, with a new bearing and seal. There was a small groove on the inside of the housing where the seal seats. Is there a remedy to this, like a different axle seal that is wider or something? Shop was like oooo yehh you need a new housing.... which is entirely possible, but, I'd figure Id do some research first before dumping a lot of money into something that it probably doesn't need. Oh and it is a dana 44 with disc brakes. Thanks for any insight

 

[CharlesHS]

Remedying the groove depends upon where the groove is located and how deep the groove is in the housing.
IF you can…. Post a few pictures of the groove in the housing.
You may be able to clean the affected area with brake cleaner and apply JB Weld depending upon the location of the groove.

 

[Wendell D]

There used to be a ring that you could install that was super thin I think they were made by Chicago rawhide. But that was many years ago!

 

[hosejockey61]

Are they aftermarket shafts? Dana 35?

More info and pics would help.

Edit: see that it's a Dana 44. Depending on the size of the groove (pics would really help here) it could be a problem. A dab of gasket maker can probably solve that problem. Make sure you are using Timken 9912S seals (has 2 ribs on the seal face).

 

[gijoejw]

Are they aftermarket shafts? Dana 35?

More info and pics would help.

Edit: see that it's a Dana 44. Depending on the size of the groove (pics would really help here) it could be a problem. A dab of gasket maker can probably solve that problem. Make sure you are using Timken 9912S seals (has 2 ribs on the seal face).

I only had the picture the shop I had it at took and it was not a good picture, so I ordered the 9912S seal and new bearing and locking ring. Im going to take it out soon and study upon it and really see whats going on. I feel like the axle they had in it, is a not so high quality one. If its crap Ill buy another axe to go with the Timken stuff. I'm not driving it atm until I figure out what to do. I feel like the 9912S seal will be what fixes it, but Ill post with pictures when I get to that point soon! Thanks everyone.

 

[gijoejw]

This is def worse than i thought. Previous owner spun a bearing and it gouged the housing…. Sooooo…. What do you guys recommend? It’s not like bad to where the bearing doesn't work, its the seal area is rough and ate up the last seal.

 

[gijoejw]

So did some redneck engineering. Welded that hole that look like was caused by a tool. Very carefully sanded it down. That’s where the seal sits and is prob the biggest cause of that leak. It’s a non rotating surface so I filled that gap pretty good. Gonna use a light sheen of rtv and see how it goes, the axle was brand new.

 

[Rickyd]

I would use rtv or some other gasket maker on the outside of the seal. Don't forget to replace the outer bearing race in the tube

 

[B1Toad]

You could try setting the seal in this: https://www.amazon.com/Loctite-5553...6-milliliter/dp/B00070LQWE?tag=wranglerorg-20

There's also a 2 part product made by Permatex that I used on a transmission that worked good, if you're interested I'll go out to the shop and get the part numbers.

Do you know if the leak was from around the outside of the seal or was it from the axle because the seal was not centered due to the damage? Or was the seal actually spinning?

 

[gijoejw]

I would use rtv or some other gasket maker on the outside of the seal. Don't forget to replace the outer bearing race in the tube

It was brand new. I felt like they had attempted to get it fixed and whoever the mechanic was was clueless.

 

[gijoejw]

You could try setting the seal in this: https://www.amazon.com/Loctite-5553...6-milliliter/dp/B00070LQWE?tag=wranglerorg-20

There's also a 2 part product made by Permatex that I used on a transmission that worked good, if you're interested I'll go out to the shop and get the part numbers.

Do you know if the leak was from around the outside of the seal or was it from the axle because the seal was not centered due to the damage? Or was the seal actually spinning?

Bearing was not spinning, its new and it fit good, drove perfectly, just leaked.

 

[B1Toad]

Bearing was not spinning, its new and it fit good, drove perfectly, just leaked.

I meant the seal, was the seal loose enough to move/spin?

 

[gijoejw]

I meant the seal, was the seal loose enough to move/spin?

Don’t know, I pulled it apart without checking which I had to pull on the seal felt like it definitely was in there sealed.

 

[Rickyd]

Don’t know, I pulled it apart without checking which I had to pull on the seal felt like it definitely was in there sealed.

Slip a new seal into the bore by itself and see how loose it is.

Make sure the seal surface on the shaft is good

 

[B1Toad]

I saved an $800 Baldwin bench grinder that was spinning a bearing race using the stuff I linked in post #9. It's been working great for over 5 years now. Paid $15 for it as a "parts only" machine.

 

[gijoejw]

The seal on the shaft was actually really good had two lips and it was nice and tight as it slipped into the housing. I put everything back together and moved it back out to where I park it. No leaks yet. I’ll drive it Monday and see how it does. If it leaks…. I’ll have to either get a new housing or find a machine shop that can weld and re mill that housing area to spec.

 

[gijoejw]

Well I can report back that I do not have a leak now! Let it sit over the weekend, drove it 10 miles today at lunch and let it sit more, nothing leaking out. Big test is the highway but looks like I fixed it!