I have done a few lunch boxes in Dana 30s before, so no big deal right? well wrong....

Only had the Jeep a few weeks before getting the locker, and noticed a small pinion leak , figured just old seal. When I pulled the cover almost no fluid came out. So I installed the spartan and bolted it all back up. I noticed it was puking oil out the pin bad, figured I just over filled. Had a buddy that is a tech at a shop replace seal for me just so I don;t mess up. Drove few miles home and seal is blown. Figured it was a fluke, replace with a Timken this time, maybe it was a cheap national seal before. first turn of Drive shaft it blew again. Now i'm stumped. Any one heard anything like this before? My buddy that helped with seal wants to pull pinion and carrier and redo it all . I'm just so frustrated right now.

Here is both of the new seals just a few miles on them . Any help or thoughts would greatly be appreciated. That and if anyone has a timken part number for the pinion seal to make sure I got the right one.

 

Your second pic looks like the seal was mashed in there. Is the yoke boogered up where the seal rides?

 

It was mashed in there good. Come to find out it was the wrong yolk, and the guy that did the install just made it fit ... With a hammer . Got a real d30 yolk from a Buddy and issue solved. Not sure what this thing is out of. Same spline but way bigger OD.

 

Wow, that's not even CLOSE!