Dana 30 Axle Seals - replacement

[dandoc]

So the YJ has bad axle seals in the front (Dana 30 w/ vacuum 4wd disconnect). I've read some online write-ups on how to replace them using some threaded rod, large washers and/or large sockets, mallets, and other various hand tools. I have the new seals (have had them for some time), but never got around to installing them myself, or with a friend. The quote for $360 from a repair shop is a bit much, even though they came down from $525. The seals likely tore when I either removed or re-installed the axle shafts early last summer. The passenger side has a definate leak, the driver's side leaks every so often.

Has anybody on this forum replaced their own axle seals? What difficulties, tips, warnings, etc., can you provide to all of us so that this procedure has less of a chance of being botched by the DIY Jeeper? Stu-Offroad has one of the better write-ups that I've seen. The help is very much appreciated!

 

[Bounty__Hunter]

I've had pretty good luck using a simple seal driver I rented from the local auto parts store, and having somebody strike it with a large wooden dowel for an extension through the axle housing and out the opposite end. It's a 2person process as one person has to hold the seal straight and keep the dowel on the seal driver as the other person runs the mallet.

 

[dandoc]

That's not a bad idea using a dowel rod, I may use that method. Anybody else have any additional tips? A concern I have is when I go to put the axle shafts back in... how can I make sure not to tear or damage the new seals?

 

[Bounty__Hunter]

Make sure there are no sharp burs on the end of the axleshafts, install them slow while trying to keep the weight off the end of the shaft going through the seal, and you should be okay.