just finishing up my sas on my 93 p/u. completely rebuilt the front axle with new everything. after driving on it about a mile, the drivers axle seal went bad. so i replaced it and drove it some more and it started leaking again.
i have gone through 3 seals on that side and it still leaks. is the tube bent?
i am about to say screw the old housing and buy an aftermarket housing, that would also eliminate the wheel spacers. does this sould like a bent housing or is it just bad luck with the seals?

 

Toy solid axle?

Did you use the centering tool to set up the shims on upper and lower trunions?

Is the seal riding on the seal surface of the axle, or is it driven in too far?

This is the long axle side, so it is harder to install the axle w/o damage to the seal.

I think an alignment shop should be able to tell you if it is bent.

 

Normally a bent housing results in a tough time getting the shafts back in. With my bent housing I had to hammer one of my shafts out and there was no way I could get it back in.

My bet is on incorrect shims.

 

X2

Generally if you use one large shim and one small shim each on the top and bottom of the knuckle you are good to go (which is what is included in the knuckle service kits I sell and have used on my own 85.

 

it is the long side i am having trouble with. i did use the thick and thin spacers that the kit came with. but that side is hard to get the axle in and out of. i will be putting in an order for a new housing from sky manufacturing in the morning. the flat spot on the birfield hits the upper part of the cup pretty good, and has a gap in the lower part.

i had planned on doing this anyways just not to soon.

 

Yup, sounds like your housing then.

 

Go for the bling and get a diamond axle housing, it'll be the last one you ever buy.....

 

X2

 

Did you do any welding on the front housing? That will warp them QUICK unless you go reallllyyyyy slowwww and take a lot of breaks.
One self inflicted warping and youll never do it again
But the 2nd rebuilding is good practice!

 

yeah i welded on the truss. but i spent 3 days doing it, 1 inch at a time.
not going to do another stock housing though. dont like the idea of wheel spacers. i have a housing coming from sky's.

 

Good job on both accounts.