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Old 09-02-2012, 05:15 PM   #1
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Leaky Rear Diff Help

Ok so ive had my 97 TJ for a few weeks now and noticed a leak coming from my rear diff which is a Dana 35. I pulled off the cover and drained it and put new sealer on the cover and put everything back together. Checked again and its still leaking but took a closer look and realized its coming from the pinion/drive shaft area. So, I pulled out the old pinion seal and put a new one. I was pretty upset when after all of that my rear diff is still leaking from that same area, possibly even leaking worse. Do you guys know what the problem could be? Im also providing a few pictures from when i replaced the pinion seal so see if theres anything wrong looking in the pics. Help a poor guy out!

Ok so this was right after i pulled the yoke and drive shaft off while the old seal was in.

This was when i put the new seal in.

This was everything after i finished the job.

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Old 09-02-2012, 07:48 PM   #2
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looks good in the pic , but
The few seals Ive changed leaked because the area on the pinion where the lips of the seal contact the pinion are worn away .
I could not get a replacement for my pinion .
What i did is bought a seal with out the outer flange and i could tap it in the diff housing a little deeper so the seal lips rubbed in new area . no leak

Don't for get to add some rtv sealant around the nut pinion area before lighting it up to seal the spline

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Old 09-02-2012, 08:00 PM   #3
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What size seal did you get and what do you mean by outer flange? Also what do you mean when you say spline? Sorry for my ignorance but im 16 and new to the mechanic thing, dont have money to pay someone to do it and would much rather learn myself anyways! Thanks for the help!
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Old 09-02-2012, 10:10 PM   #4
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Your seal has a flag that sits on the out side of the differential It the part farthest from the rubber .
It stops you from driving the seal in to far .
I bought a different seal from napa for 10 bucks that had no flange, so i can tap the seal in 1/16 to 1/8 deeper where the steal on the pinion is still the original thickness.
you get a tight fit no leak.
You mite try taping your new seal with a wood block 1"x1" and bending the inside area ( space between the flag and the rubber) back a bit so the rubber makes contact with a new area on the pinion .
In your 1st pic i can see what looks like a groove on the pinion where the seal rubs .
It could be some dried grease that is causing the leek.
You could clean the pinion with emery cloth .
You could try grinding the flange off the seal , Ive never tried this .

The spline is the part that has the groves that the pinion slips over . pic 2
you could put some rtv (blue stuff) behind the threads on pinion shaft or under the nut on the out side . or both ?
If your pinion nut is not (balls tight ) you can get a side to side wabal on the bearing and this will cause the seal to leak or if the bearing went bad it could cause the seal to leak .
how many mile do you have on your tj .
john
wish i was 16 years old
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Old 09-02-2012, 10:19 PM   #5
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I have 157000 on it. Ive owned it mabey 5 weeks and already the diff is annoying me and the power steering gearbox is leaking.... im semi following you on most of it. How did you ask for a pinion seal without a flange at the parts store? Do most carry stuff like that?
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Old 09-02-2012, 10:47 PM   #6
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If you go to auto zone they can bring up a picture of the seal, i bought one the other day for my rubi d44 front axle.
They should have a few options get the price one .
At 157 000 you should check the bearing it may have killed your seal.
It cant have any slack up, down, left, rite.
You can rebuild the steering box , or get one out of a junker with low miles.
If it breaks just fix it. There are 2 kinds of jeeps 1 broken jeep 2 jeep that will be broken . Is the pinion scratched up where the seal rubs?
John
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Old 09-02-2012, 10:53 PM   #7
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So the pinion isnt supposed to be able to pivot around when the yoke is off? Mine did. Ill check for scratches also. Ive also heard that if there is a groove in your yoke it can also leak from that, is that right? Ill probably head to the junkyard this weekend to pull a gearbox from a durango and possible a yoke from a cherokee... Thanks for the help though so far! Very smart answere!
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Old 09-02-2012, 11:11 PM   #8
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Ohhh i just realized what you meant. No the pinion doesnt wobble when everything is connected up. How do you tell if bearings are bad? And when you have the seal with no flange do you put it on first and then put the second one with the flange on over top of it? Will rtv sealant mess anything up in there if i just fill her up around the piston and stuff?
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Old 09-02-2012, 11:46 PM   #9
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bearing. You must not have any wobble up, down, left, rite when its all time .
slack 1/8 turn is normal back and fourth .

The new seal will be press fit you could use some rtv if you want around the edge .
only use one seal .
Nooooooooooooo don't filler up I'm talking about a finger full around the pinion to seal the space between the shaft and the yoke ( yoke is a new word i forgot, i was calling it a pinion in earlier post . ) this should help.
The grooves in the( yoke ) cant really be seen buy eye but they let fluid slip by .
Its hard to find a good yoke mine where groved at 75000 mils
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Old 09-03-2012, 12:08 AM   #10
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Ok thanks for the help! I guess ill look under there tomorrow and use some rtv on the yoke. Hopefully that works. I love jeeps but ive had it like a month and already have to replace steering gearbox, fix the rear axle whatevers wrong with it, replace soft top, and now replace oxygen sensors.......
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Old 09-03-2012, 12:22 AM   #11
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Subscribed.
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Old 09-04-2012, 10:59 PM   #12
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how do you subscribe? i noticed a leak today.
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Old 09-04-2012, 11:11 PM   #13
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You just subscribed by posting in it.
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Old 09-04-2012, 11:32 PM   #14
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Seems like you may already have a handle on it, but here's a youtube video of the process.
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Old 09-05-2012, 10:17 AM   #15
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This is a project I have on my list as well.
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Old 09-05-2012, 03:48 PM   #16
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Quote:
Originally Posted by Heliotropic
Seems like you may already have a handle on it, but here's a youtube video of the process.
This video is perfect. About to get started. Didn't realize it was that simple. Guess I just needed to see that. Still nervous that my pinion bearings are shot .
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Old 09-05-2012, 04:05 PM   #17
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Quote:
Originally Posted by Heliotropic View Post
Seems like you may already have a handle on it, but here's a youtube video of the process.
Well like i said ive already replaced the pinion seal correctly but it was still leaking there. I was trying to figure out why

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