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leaking front axle

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Old Apr 13, 2010 | 08:59 AM
  #1  
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leaking front axle

So, my front axle starting seaping and dripping GEAR oil from the left side, the last time I threw it into 4WD. Can someone tell me what this is, what the importance is, and whether it is safe to drive the vehicle if the hubs are in FREE mode and 2WD? I figure it is obviously oil from the differential, but what are the consequences? Last I knew, axles were not lubricated with gear oil, and the worst case scenario is that maybe my gear oil is too low for operating 4WD?? Is it possible I trashed my gears in there? I drove about 14 miles offroad before realizing it was leaking. (How is one supposed to see these things without checking his/her truck every 2 minutes?)

Thanks.

F250, 1999, 4WD standard.
 
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Old Apr 13, 2010 | 09:52 AM
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Its the inner axle seals that seal the diff off from the axles tubes. I just replaced mine this past weekend. Its quite a job, not hard just takes a good amount of time. Both sides need to be torn down, axles removed. Then the carrier needs to be removed from the diff and the seals come out into the pumpkin, then new pressed in. The only worry i would have is water going down the tubes and getting into the diff and contaminating the fluid.
 
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Old Apr 13, 2010 | 10:05 AM
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I was getting a solid: drip . . . drip . . . drip (every second or so). Should I not be worried that the level will get too low, or is it more along the lines that the gear oil will only leak when the 4WD is engaged and the oil gets hot?

Sounds like a big job. Do you think the problem is a bad seal(old), or is it likely I've got some rust in there and that has created the problem? I've heard of rust inside of there causing the seal not to seat properly. Although, I'm wondering/thinking that it would be pretty hard for water to get down in there to cause rust or contaminate the gear oil. Unless I'm running in water or really wet mud. Neither of which is a habit of mine.
 
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Old Apr 13, 2010 | 10:12 AM
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The inside of my axle tubes are really rusty, result of the outer axle dust seals being trashed for quite some time and living in Utah 6 months out of the year is wet. The outer axle seals are very poorly designed as well and usually fall apart within months. I had rust all the way to the seals. My driverside was leaking and i noticed a little rust under the seal which i think was causing my leak. not really sure. So i buffed it smooth again so the new seal would seat. You will only lose gear oil til it gets to the bottom of the tube, but that is about 1/3 of capacity, which would cause problems. Mine would always leak after using 4wd and i think when the axles are moving it draws oil out of the diff faster than if its just in 2wd.

The only way its going to get out of the diff is if those seals are bad. Also the breather on top of the pumpkin can get plugged up and cause the pressure to push oil out of the seals. Sometimes if you are lucky you can just un clog that and it might stop. But if its a solid drip then i'm sure your seals are gone.
 
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Old Apr 13, 2010 | 12:41 PM
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N20 is right about the above ^^.When the seals get bad they will seep or leak fluid into the tube and then it gets by the knuckle seal and dust seal.I have changed mine as well because one side was leaking.It is a pain in the *** but it can be done.I put the pumpkin on ice so it would slide back in with no fight.
 
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Old Apr 13, 2010 | 12:45 PM
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My carrier came out with a few pushes of the pry bar and went in with a few taps of a rubber mallet. But i've heard they can really give you grief, thats why guys put them on ice or heat the case.

RiverRat- How far did you tap your seals in? Did they go and just stop when they were seated or did you just stop when you thought they were in the right place? I just hope i have mine in there good. Cuz if it leaks again its going to stay leaky!
 
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Old Apr 13, 2010 | 01:02 PM
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I took a picture of the old ones still in the case so I installed mine just like the others were.I think the outer metal ring was flush with the casting.I bet you will not have trouble for a long time.
I understand totally what you mean about a PITA.I will have a better setting tool besides the homemade one next time.Those seals have to go in straight or you will mess them up.
 
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Old Apr 13, 2010 | 01:09 PM
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Yeah i used a piece of roundstock i had laying around that was just under the diameter of the seal and a length of 1/2 inch conduit throught the axle tube that my buddy tapped while i made sure the seal seated good.

I seated the passenger side so the face was flush with the groove going around the machined race and the drivers side face was flush with the bottom edge of the beveled race. I think thats where the old ones were sitting. I stopped tapping cuz it felt like they weren't going to stop and i didnt want to punch them through.
 
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