after replacing 3 sets of front axle seals on my 99 ram and still not solving the left side inner axle seal from leaking my mechanic after ruling out all other possible causes discovered that the axle was manufactured wrong.this truck has 64000 miles and has been leaking on and off for about 20000 miles.i know that this is a dana assembly so i would think that it was thier mistake.

in the picture that i attached the old axle is the one that is closest to you and if you look at the machined area where the seal rides it is not machined properly compared to the new axle.the seal on the old axle was riding part on machined surface and part on none machined surface causing it to leak.i'm posting this in hopes of helping someone who has the same problem and i have seen some threads about this.

click on pic

 

Wow. I can see how that might cause some trouble..... Wonder how that one got past Q/C......

 

you'd be surprised how much stuff makes it past q/c in parts suppliers like dana. Went to school with a guy who worked at a shop that made parts for holset (now i believe its cummins turbo technologies) and holset was sending back about 30% of the parts sent from the manufacture (that made it threw the manufactures QC

 

hmmmm....good tip....ive replaced my pass. axle seal 3 times already....within the past 10K on the truck...and again she is leaking.....and last time i did it, i know for a fact that it was seated in all the way, for i didnt have problems for about 2 months....ive been running with it leaking for about 3 months now...and i just fill it up when needed...for i dont feel like taking it apart again....


Also i have found at my local dodge dealership that there are boots to put on the outside of the axle tubes ( you know how you can see in) well they prevent dirt, grime, and water from entering the tube...these are all causes of why they can leak...