Topic: T-Case Leaking! Need help with correct setup.

[Big Pap Dog]

Today, pataco13 and I took my truck for a little drive so that he could experience the different ratios of a Dual Ultimate and catch the "bug".  When we stopped the truck, I was showing him how the FROR crossmember mounts up and we noticed that the rear seal was dripping gear oil.  I'm kinda pissed because the cases only have about 500 miles on them and I haven't even wheeled it yet due to no front driveshaft.  I do not drive my truck hard so i'm wondering if it is just due to the rear suspension setup, which consists of:

-cv driveshaft with cv at t-case end
-4" Marlin springs with 1" longer than stock shackles
-pinion is not rotated yet/perches are stock and i have no shims
-5:29 gears with ARB
-Front Range crossmember not clocked and no drivetrain lift

With the pinion not rotated and cv'ed shaft, have I prematurely ruined the seal by driving it this way?

How can I prevent this?

Here it is illustrated for all to see:

[MiniSimp]

Remove flange
Replace seal (use lots o grease inside)
Re-install flange

[emsvitil]

The rear pinion nut may be loose, it seeps oil when it is loose.

I would also check for nicks on the mating surface of the flange.

[Big Pap Dog [OP]]

Remove flange
Replace seal (use lots o grease inside)
Re-install flange

So is that the trick?  extra grease?  Replacing the seal is simple, but if its just going to wear out in another 500 miles then I must be doing something else wrong.  I don't believe the cases are overfilled either, I used the measurements from the Marlin website for the dual case installation. 

[emsvitil]

Also smear RTV on the splines before installation to avoid a leak path....

[*ROKTOY*]

X2 on the grease, also make sure you use the RTV in the splines of the flange.

[Big Pap Dog [OP]]

Thanks everyone for the help!  I know these things happen, I was freaking out because I haven't had duals in the truck very long....but i just realized that they sat in storage for like 2 years (dry).  That probably helped accelerate this problem. 

[PA_taco_13]

i'm sorry Noah...i didn't mean to break your truck 


but i do want a dual ultimate now   

[79coyotefrg]

but i do want a dual ultimate now   

  me thinks he got bit by the bug