I have a 2005 Ram 3500 4X4 with the AAM 9.25 front diff.
About a month ago or approx. 1800kms ago I replaced the front axle wheel end u-joints. When I removed and installed the axles I took care to center the axles in the axle tube and try not to damage the axle seals. When I installed the axles I also greased the area where the the seal rides.

About a week ago (or 200kms) I drained and replace the diff oil and now I noticed the passenger side developed a oil leak at the axle end. When I filled the diff I filled it until it was level with the fill hole. I did some research and some guys are saying if the diff is overfilled it can cause a leak at the axle seals. So I drained the oil to about a 1/4 inch below the fill hole and then I washed off the area around the axle end. I then went on a hour drive and I reinspected to find more fresh oil.

My question is, is it possible that I overfilled the diff causing the seal to leak since it didn't leak in approx 1600kms from the time I did the u-joints to the time I changed the oil?
Now that I drained a bit of oil, is it just residual oil in the axle tube?
Why would it leak out thru the pass side and not the drivers side if it was caused by the overfill?
Is there a problem with these seal and should I replace them?

Thanks for any info and help

 

It shouldn't leak regardless. It is probably just getting weak and when you moved it around by pulling the axle, it is not sealing like it should. The rubber is probably not as soft as it once was and the spring inside the lip is ages as well.
Oil is supposed to get into the shafts to lube the axle bearings and under normal driving, it is going to slosh up in there even if you run it a little low.

 

I have an 08 Ram 2500 4x4 6.7 Cummins. In the 1st 75k miles, I've had to replace both differential axle seals. Probably made in Mexico from cactus. No excuse for Dodge to have such crappy seals.