Inner axle seal replacement

[DieselFam]

My ball joints are shot. My hubs are shot. The axle is leaking at the passenger side end.So I have to tear down the front axle and re do alot of things. I have the Warn Premiums, Timkin hub bearings, dust seal, knuckle seal, Moog ball joints, and u joints (just in case).

My question is. If there is a leak at the outer end of the axle tube, that should mean that the inner seal (inside the diff) has gone bad. Is this correct? By the way, I have NOT added any oil to the diff recentley. If so, how hard is it to replace that inner seal? I have torn down axles before all the way to the "c" but never have done any work on a diff. I usually leave that to the pro's. I have never done any shims or lash or had to spread the housing or anything on differential. Is this do able in the driveway or should I pony up the labor cost ($680.00) to have someone do it for me. I would love to keep the money for other upgrades. Any help would be appreciated.

THANKS.

[strokin'patty]

first look at the axle housing (which ever side you think is leakin) if its wet around that little dust boot then yes, the inner seal is bad.. now this job aint rocket science, but it aint easy either...

-put the truck on jack stands
-remove wheels, brakes, hubs, everything all the way to the spindles on both sides...
-next, the tie rod that connects the driver and passenger ball joints, drop it outa the way, since you gotta replace the ball joints to, plus its just way easier for the next steps.
-then pull the diff. cover off, let the fluid drain.
-now pull the axles out, you will probably have to take a prybar and pry on the U-joint to pop them out.
-once the axles are out, your gonna go back to the diff.
if you look on either side of the differential carrier assembly you'll see 2 bolts per side holding on the Carrier bearing caps . just unbolt those to remove those caps that will expose the inner bearings for the diff.
-now with a prybar, pry upwards and out to pull the carrier. (keep in mind its got some weight to it, so you may need a buddy to help catch) DONT LET IT FALL!!
-the carrier may take some muscle, but it should pop right out with the proper leverage.
- once the carrier is outa the way, you'll need a long enough prybar or something that you can stick down the axle housing towards to differential housing and with a mallet tap the seal out so that it will fall out where the differential was. depending on your year there may be a plastic looking cone in the housing down towards the seal. try not to mess that thing up or you'll be replacing it to.
- once you've popped both seals out clean the area very well. brake clean works good.
-now prep your new seals by puttin a light coat of axle grease around the edge of the seals. place them in there spots and lightly tap them in so that they are snug and reset in the same place to old ones were.
-since you removed the carrier as a whole no backlash adjustment will be needed. lucky for you!
-now place the carrier back in its place bolt it down, not sure of torque specs, wouldnt hurt to look it up, but just make sure its tight without goin crazy and breakin stuff.
-clean the axles off and slide then back into place, may have to jiggle them in to get them to spline in right.
- take some real seal and put a light bead around the differential cover place back on the housing and bolt it down. clean excess real seal off and smooth around edges.
- also since your there might as well put new outer seals on with the hub assemblies and DONT FORGET THE DUST BOOTS BEFORE YOU PUT THE AXLES IN!!!
- put the rest back together as you took it apart.
- it would be best to allow the real seal to dry for a good 8 hours at least befor adding differential fliud. autozone can tell what fliud to use if you dont know..

well good luck with it all, like i said it aint a bunch of math and calculations, but it is a good 5 hours or so of work depending on your skill level. i recommend goin to autozone and tell them your doin an overhaul on your front axle and you need all the seals for your make and model.. that way you shouldnt forget anything. any more questions for more detail or whatever just ask... I'm a mechanic in the Navy so i've done this job quit a few times. still annoys me everytime too. but like i said good luck.

[strokin'patty]

oh and i forgot to mention.... since your hub is off might as well replace the wheel seal and inspect and regrease your wheel bearings.. if they have burn marks on them, then time to replace em.

and a quick list of tools and supplys

impact gun and sockets with a swivil joint for removal of spindle to hub nuts
prybar and or something long too for reachin the inner seals
mallet
basic wrench set
basic socket and rachet set
socket big enough for hub nut- at least a 1 incher if i can remember
needle nose plyers for hub disasembly
allen wrenches for removal of wheel speed sensor

SUPPLYS

inner and outer axle seals
wheel seals IF bad or leakin.
axle grease
inner and outer wheel bearing, IF burned up
brake clean or some sort of solvent
shop rags
grain pain
diff. fluid

should be it..

[DieselFam]

Strokin' Patty
Thanks so much for the instruction. I have taken a few axles all the way down to the ball joints and or king pins before, but never done anything inside the diff. Your details were exactly what I was looking for. I am going to tackle this thing Saturday. Thanks again and thanks for your service to our Country. I'll let you know how it works out.

[powerstrokin87]

mine axle seal is leaking too, its dripping on the tire when the truck is parked I guess this is the inner axle seal too? Let me know how it goes Dieselfam i might be doing the same thing soon.

[strokin'patty]

Originally Posted by powerstrokin87

mine axle seal is leaking too, its dripping on the tire when the truck is parked I guess this is the inner axle seal too? Let me know how it goes Dieselfam i might be doing the same thing soon.

yeah bro, if yours is leavin fluid after everytime its parked, you can pretty much garuntee its gone... hope you dont have any water or mud up in that diff. that can cause a looooooooong day either stuck somewhere off road, or just an expensive parts list.



and dieselfam no problem man, just tryin to help. and I appreciate your appreciation for the troops. when we say thanx, we mean it. let me know how it works out man.

[powerstrokin87]

Does $38 a piece seem like a high price for inner axle seals?

[Cark]

i just got one (by mistake) from napa and it was only $14. That's for the dana 60.

[powerstrokin87]

I just left napa and 1st they ordered the wrong one then they told me $72 a piece!!

[82332]

Searching threads for this same problem, I have inner seal leaking too. The bummer part, I recently install new ball joints, u-joints, hub seals, one hub, and dust seals. I hate pull that all apart again. It was a royal pain the first time, very rusty. I hope it will be easier this time.
I am wondering if I'll have to replace the hub seal again?

2002 F250 4x4