Whether you have manual hubs or not, there will be a knuckle seal behind it. I wouldn't worry about the dust seal, and if the knuckle seal comes out without damage, just reinstall it. You'll want the OTC knuckle seal install tool, it installs the seal onto the shaft, and installs the assembly into the knuckle.

 

I have the same year and model truck and had the same problem. My dust seals were shot and I opted to have the dealer (in Riverton of all places haha) replace all of the seals including the knuckle seals mentioned by Gaius while it was torn apart. The dust seals are superseded with a newer material. Personally I hate to get deep into a project and not replace seals and wearable parts especially if you have high miles on the clock.

 

The dust seals are superseded with a newer material. Personally I hate to get deep into a project and not replace seals and wearable parts especially if you have high miles on the clock.

the dust seals are 100 % redesigned and relocated to the axle tube instead of riding the axle shaft and actually work now lol

 

dbl check
PLAT-SPICER-KIT39

 

I got some new seals with my U-Joints and discovered that much of the front end needs replaced. I have new wheel bearings on the way as well as new inner axle seals and an install tool. I will have to order the vacuum seals tonight as they are all torn up on both sides as well. I noticed that my dust seals don't come close to fitting. They slip up into the hole like they fit but they aren't even close to staying put. It's very possible that NAPA gave me the wrong parts. They sold me an SKF 16510 and without a welder, there is no way that dust seal is staying in place. I don't mean it's just a little loose....it doesn't fit at all. Has anyone else encountered this?

 

it should fit you have coil springs correct ?

fast forward 8:02

 

it should fit you have coil springs correct ?

fast forward 8:02

I totally hate you for posting this (lol), i put those pos seals back in last summer and really wish i knew about these updated ones

 

I have coils. Here is a better video. Mine fits just like the one in this video. I'll have to find a driver tomorrow and give it a few good whacks.

 

My vacuum seals are worn out, too. Should I replace them even if I don't have auto hubs?

 

So I have a question about the nice little plastic alignment tool. How am I supposed to get that on the shaft and in the tube but still between the seals? I feel like it needs to be on there to help guide the shaft through the inner seal but getting the outer seal in place with the shaft in the hole is confusing to me.

 

that collar / guide should slide back into the axle tube and not hinder your seal install AFAIR
a lot of Dana axles don't use that part you just need to be mindful off the inner seal when installing the axle

 

Got my superseded inner seals (2019816). I am thinking the right picture is the side that points OUT. Am I right?

 

Next problem......axle alignment with diff. My truck did not have the guide inside the tube to help the axle shaft align like the one found here: QU20039 Inner Axle Shaft Guide Excursion, 1999-2004 Ford F250, F350
I did have a big, flat washer looking thing. The problem I have is that the washer slides on the axle past where the seal rides. I couldn't get it in the hole with the new outer dust seal in place. I tried to set it in the tube so that I could stab the axle into it but the diameter is just smaller than the inside diameter of the tube and it would fall over. So what I did was to put a layer or two of tape around the outside of the washer. Just enough to hold it up right but not enough to prevent it from sliding inside. I set it about 3-4 inches in from the outer side of each tube. The idea is to be able to stab it right away after the splines clear the dust seal, and then go with the axle until it meets the inner seal. The stepped down sealing surface of the axle will allow the washer to push past it but will stop if from travelling way down the axle shaft and becoming useless. If it works I'll post pics. If it doesn't work I'll be ordering the part from torque king and possibly new dust seals as well.

 

Success! The plastic rings are not alignment tools, evidently. They are a part of the old dust seal. Either way, they worked to align the shafts into the diff. I had to tack weld the new style dust seal onto the end of the tube because it wouldn't stay. They are a new and revised version of the old ones, but they are still lacking in their ability to stay put.