Let's Play A Game (Do U see what I see)

[Shrek]

The two photos on the left are of a leaking pinion seal that is still in the car.

The two photos on the right are of a non leaking pinion seal on my shelf.

Who can guess why this pinion seal is leaking???

[GOLDCYLON]

Tear or compromised seal ?

[tccrab]

Almost looks like the seal is in upside down.
The rubber part of the seal is outside the seal itself and is riding up the shaft of the pinon.


and....the nuts are loose on the two right pictures.

'Crabs

[Shrek]

Here's a hint.

Look at the stamped steel dust cover pressed onto the yoke.
Now think about where the lip of the seal should ride.

[geezer]

Seal , what seal!

[lfalzarano]

How about the hairline crack in photos 1-2


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[IM28702]

Lack of RTV on the outside of the seal between the seal and the housing?

The lack of the dust cover will change the diameter where the seal rides. Why isn't there a dust cover on the leaking unit?

[Shrek]

How about the hairline crack in photos 1-2


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Yeah...I'll be addressing that issue after I get it out of the car.
Hoping it's not actually a crack. But doesn't look good.

Sucks because I've had his car since Nov and tending to a long list of repairs and maintenance while he got settled into his new place.
I was done and ready to send it when I found this crap during my final inspection.
He's cool, he said keep it till spring if I have to.
Hoping I can take care of this last problem and send it north before his first snow.
If not, it'll keep the wife's Z company for another winter. :)

[Shrek]

Lack of RTV on the outside of the seal between the seal and the housing?

The lack of the dust cover will change the diameter where the seal rides. Why isn't there a dust cover on the leaking unit?

There is a dust cover!

OK here's my assessment on the leak. Could be wrong but this is how I see it and won't know for sure until I get it out of the car.

Back in the 90s, Vette Drs swapped in a 4.09 gear and I'm guessing the pinion shaft/spline diameter was smaller, so they used a smaller yoke/dust cap that retained the 1350 u-joint.

Fast forward.....A shop recently installed a new seal and probably ordered a stock Dana 44 seal not realizing it had a smaller diameter yoke and dust cap. Then proceeded to install the seal lip over the dust cap.

I'll verify all of this when I get the rear out of the car.
Hopefully it's any easy fix and the case is not cracked as pointed out by lfalzarano.

[IM28702]

Ugh... Ya, that ain't gonna work out so good.

[BigJohn]

The two photos on the left are of a leaking pinion seal that is still in the car.

The two photos on the right are of a non leaking pinion seal on my shelf.

Who can guess why this pinion seal is leaking???

Cracked!

[Shrek]

Finally got around to tearing it down to repair the leak.
It's exactly as I predicted it was.
The 4.09 gear set has a smaller 26 spline pinion shaft and yoke.
They installed a stock dana 44 seal that was obviously too large to seal properly and assumed it would be OK riding on the dust cap.

***EDIT***
Found the correct seal (Spicer 44895)