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I have replaced my driver side rear axle seal many many times....I think that these speedi sleeves may be the answer to my problems. But where do you get these things. I have never seen them. Are they known by any other names?
I've heard them called Quick sleeves. I found them at bearing shops. The place around here is call Applied Industrial Technologies ( a.k.a Bearing inc.) I had this same problem with my axles and I found the cost difference wasn't that much just to replace the axle. They quoted me at $25- $35 bucks for one Quick sleeve.--kinda pricey for what you get. Hope this helps.
Try a different brand of seal or grind off some of the flange all you need is for the seal to sit in a different location and get out of the groove. Before doing anything check the axle for straightness because if it is bent the seal wont seal. Also when installing the seal smear a little silicone around the out side of the seal and maybe the bearing too because it may be leaking around the outside of the seal and not the bore. Go to an industrial bearing shop and you will find other options for a seal instead of what ford put in there.
I have used these things before and had success. Just be sure to use some sealing type locktite(green I think) otherwise when the grease gets good and warm it will weep under the sleeve and make a hell of a mess on the inside of your drum.