How to replace a pinion seal on your TJ

The "right" way would be to drain the fluid, pull the wheels, pull the brakes, remove the carrier, remove the pinion, replace the crush sleeve and rebuild the whole thing to factory specs. That takes 4-5 hours for a pro and a busload of specialized tools to do correctly. An amateur will likely never get it right. The fix will likely last for 10+ years. The "down and dirty" method above takes about an hour and will last for 10+ years unless you screw it up royally. If this was a brand new race vehicle, I would say spend the extra time and money. This is a 15 year old Jeep- save the time and money.
 
I just took a pic of the real diff seal and it does not have the cover (oil slinger) either, which tempts me towards using the Mopar part I bought without the cover/slinger.

IMG_0524.webp
 
The "flush seal" is Dana Spicer 50531

I installed the same pinion seal you did prior to heading to Moab a few weeks back and have not had any issues. My jeep has rubicon axles front and rear. I'm not concerned with running without the dust cover. Actually, in my case I swapped the yokes to match my driveshafts (1310). When I did that the yokes made a grinding noise on the dust cover so the fix was to remove it.

redoing my seals Rock Auto has DANA 50660 as the seal, I checked on Denny's Driveshaft and he has the same part #. The one you have listed per Denny's is for a dana 50 solid. Is their a difference between the two? Update, I see the 50531 is for TJR and used for other axles i.e. dana 50. I ordered both to do a comparison.

Per R.A. Specs:

dana 50660
Axle ModelDANA 30/44
Inside Diameter (IN)1.552
MaterialRubber
Thickness0.567" IN


dana 50531
Axle ModelDANA 30, DANA 44
Inside Diameter (IN)1.552
MaterialRubber
Thickness0.629" IN
 
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For those who have the tools and want to set the pinion pre-load properly, you need;

250lb torque wrench although you can make do with a breaker bar if you're careful.
1-1/8" socket to fit the torque wrench/breaker bar.
An accurate dial-type inch-pound torque wrench (and probably socket drive adapters to fit the big 1-1/8 socket)

Understand that any torque setting means absolutely sweet FA. It's just a starting point, especially if you've replaced the crush-sleeve - which is not usually necessary. With the driveshaft, wheels, and drums removed, you use the inch-lb torque wrench to see how much rotational force is required to rotate the pinion shaft BEFORE you do your final tightening. You would do this while you still feel slight play in and out, like after you've changed the seal, installed the yoke/nut, and taken most of the slack out.

For instance, I measured mine at 9 in-lbs. The Dana 35 is pretty puny so it doesn't take much to turn it.

You now incrementally tighten the nut 5 - 10 ft-lbs and keep checking with the in-lb wrench looking for a 5 in-lb increase in rotational force. This is the only accurate way to know that you've compressed the crush sleeve enough to put the correct preload on the pinion bearings. It doesn't take much rotation to overdo it. Back it off if you've gone too far. If you exceed 300 or so ft-lbs - need new crush sleeve. I used a big pipe-wrench to brace the yoke while tightening the pinion nut.

In my case, the seal wasn't leaking. Just wanted to take the play out after 130,000mi. I wound up turning the nut 30-50 degrees to achieve this.


Actual just read about this in the TJ SM 3-101!!! I am changing mine and viewing all the info before I get it changed!!
 
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