Leaking Dana 60

[Spikedog08]

So last year I put a new gear in my Dana and ever since, it leaks . . badly.  So I took it back to the place twice and still leaks . . badly.  SO I called another mechanic friend and he said he will fix it up . . just get a new seal and a "redi sleeve"?  So I called the dealership and have ordered the seal but they didn't have anything for the sleeve.  What am I looking for exactly?  Thanks in advance . . .

 

[Burdar]

It's a thin sleeve that is installed over the sealing surface of the pinion yoke.  There is probably a groove worn into the yoke where the seal rides.  The sleeve will make that area flat again so the seal should be able to do its job.  They make them for the engine's harmonic balancer too.

https://shop.advanceautoparts.com/p/yukon-gear-redi-sleeve-yoke-saver-for-875-c-925-c-dana-60-dana-61-dana-70-dana-70u-dana-70hd-30228/11643323-p?c3ch=PLA&c3nid=11643323-P&adtype=pla_with_promotion&product_channel=online&store_code=&gclid=EAIaIQobChMI3ujOv8Py6QIVTNbACh0IVwRkEAQYASABEgJPVfD_BwE&gclsrc=aw.ds

[jamesroney]

So last year I put a new gear in my Dana and ever since, it leaks . . badly.  So I took it back to the place twice and still leaks . . badly.  SO I called another mechanic friend and he said he will fix it up . . just get a new seal and a "redi sleeve"?  So I called the dealership and have ordered the seal but they didn't have anything for the sleeve.  What am I looking for exactly?  Thanks in advance . . .

Hi, I recommend some root cause analysis before you continue to replace parts.  I think you did the right thing by changing the seal the first time...but after two tries, it's time for some troubleshooting.

WHY is your "Dana" leaking, and where?  There are several failure modes to investigate. (most to least likely...)

1.  Improper sealing surface on pinion yoke.  This is obvious, and easily detected.  Anyone that changed the seal twice would have seen the damage, and should have serviced the yoke.  A sleeve is the redneck way to patch it.  Replacement Dana 60, 29 spline 7290 series yokes are readily available.

2. Improper yoke to seal engagement.  This happens when the seal is installed backwards, wrong seal, or incompatible seal to yoke shield is used. 

3. Improper pinion bearing pre-load.  If the pinion pre-load is wrong, then there will be excess radial play at the seal to yoke interface.  This is difficult to detect, but fairly common.  Loose pinion nut, improper cup seating during assembly, wrong shim pack, etc.

4.  Improper sealing surface on seal to housing interface.  This is more difficult to detect, and fairly rare.  If someone gouged the housing bore the gear oil can seep past the seal. (or if the housing bore is rusty, dirty, or the seal is improperly installed)

5. Inadequate fit between shaft and yoke splines behind the nut.  Easy to detect, very rare, and results in a relatively low rate of leak.  Easy to mitigate with RTV goop under the nut and washer.

For me, sleeving a $50 yoke is a last resort that I have never had to do. 

[jt4406]

At the risk of "getting run outta town on a rail" I would like to refer you to another web site where I was working on the same problems with my dana 60  ⠀⠀⠀⠀⠀⠀⠀⠀⠀⠀⠀⠀     

https://board.moparts.org/ubbthreads/ubbthreads.php/topics/12625/re-dana-60-axle-seal-question-update.html#Post12625

quote from above...

I checked at the local Napa for the 67 Ford 1/2 ton pickup with 9.75 dana. The seals listed for it fit!
They are Napa part # 15142 for those of you who may need them. They are a little smaller than the ones the parts book listed that wouldn't fit, just like the doc said.
Also, some more info for you guys doing your own boogie with a dana 60. I needed a "speedy sleeve" for the yoke (a sleeve that fits over the groove worn in the yoke by the seal and 30 plus years of use). All three parts stores in town listed the sleeve, no one had it in stock, but were glad to order it for me, at the cost of around $25-$30 bucks. I asked a lifelong parts man about a sleeve, he looked at it, says "I think I have what you need" (didn't look it up) walked back up from the back with Carquest # A226-2 sleeve, fit perfect, $6 bucks!!
One last thing, Dr. Diff, the axle bearing locking collar is still available by itself, Timken # K108601 (from A&W Bearing in Texas).
Thanks for the help guys.


Jess in ky

[Spikedog08]

Also make sure the vent is not plugged I’m told . . Which they did not do when I asked.  Guess that could be the issue.  Hope to have this fixed soon . . Most of the fluid has to have leaked out from the puddles I’ve cleaned up . .