Axle tube leak - Dana 30

[tutone]

My Dana 30 front axle is leaking from where the passenger side axle tube goes into the carrier housing. It leaks both from around the tube, and from where the housing is spot welded to the axle tube, or at least that is what I think it is.

You can see I tried to seal the outside which I didn't expect to work, and it didn't.

It is also leaking out of the passenger side axle tube by the wheel, so I knew I needed inner & outer seals, so today I pulled the axles and the 3rd member. I kind of assumed the inner seal would take care of my leak near the carrier housing, but now looking at it from the inside with the seal removed, I don't think it will stop the leak.

Is this where the oil is going that leaks out of the axle tube to carrier housing area? If so, what is the best way to resolve this? Can I clean it up, seal the inside? Should I pull the axle and weld it (I don't want to have to do that.) Or is this poor Dana 30 trash?

 

[Tricky Dick]

I would clean it and smear some Ultra Black on the inside. I've noticed some sort of sealant around the tube on a few modern axles I've had opened up.

 

[Broncobowsher]

I remember vintage race photos and that is where the front axle would break at. I would be worried that the housing might be reaching that point after decades of use.
How large of a tire are you running? Or have been running? Lots of off-road flexing would be putting torsional stress on that joint as well. Street miles with small tires should never see that as a problem.

Probably overkill, but I would look for a good welder who would do a full 360° weld of the tube to the housing. Steel to cast iron, soaked with gear oil, won't be easy. But more structural that RTV.

 

[SteveL]

What size tires and what are you doing in the Bronco? If you have bigger tires and or go off road frequently no sense polishing a turd. Get yourself a 44 or a 60 if you're an animal.

 

[tutone]

Running 31s, don't really know the history, but the 31's are from the 90's. My plan is to go to 33's soon.
I thought Ultra Black was probably the right thing to use but I didn't have any. After lots of carb cleaner and air, I squeezed as much anaerobic gasket maker as I could get in there. It's that bright red/clear gasket maker. We'll see how it holds.
I'm not in the mood to pull this axle right now, and the truck does not get heavy use. I think I'll look for a 44 to build for it, or a clean 30 housing I can prep. 44's seem like they are ~ $1k any more.

 

[SteveL]

Running 31s, don't really know the history, but the 31's are from the 90's. My plan is to go to 33's soon.
I thought Ultra Black was probably the right thing to use but I didn't have any. After lots of carb cleaner and air, I squeezed as much anaerobic gasket maker as I could get in there. It's that bright red/clear gasket maker. We'll see how it holds.
I'm not in the mood to pull this axle right now, and the truck does not get heavy use. I think I'll look for a 44 to build for it, or a clean 30 housing I can prep. 44's seem like they are ~ $1k any more.

If you're going to slowly put an axle together all the more reason to go 44. I think there are currently a couple in the classifieds.