I have been building race differentials for years, pulled the front apart to replace bearings, seals, new CV axle on driver side, new Mopar seals & mounting bushing, everything went great, reinstalled with no problem, test drove 2 miles & gear oil pouring out between seal & new axle, pulled down & replaced that seal twice with the same results, can’t see a problem anywhere, very puzzled, please looking help, customer trying to get back home from storm on the east coast

 

Cant I have ran into that problem.... But sounds like Wrong Parts to me in this case....

 

I used OEM Jeep seal & new Precision CV axle

 

This is not an SRT? Correct?

 

Sure sounds like an inner seal issue? Seals fit the axle tight?

 

It’s not a SRT

 

It leaked the same with the old axle as well as with the new axle, changed seal twice

 

OK.... But...... Did you test fit the seal to the axle ?????? If not, I would would suggest that you do so.
Post up some photos if you can.... Something is just weird here... 4 seals and they all leaked... Mind boggling to say the least.!!! Will help you find it if we can...
I'm sure the customer is not happy at this point....
But now's the time to fix it !!!

 

If you overfill the axle it will squeeze it out when it heats up and expands. Had this issue once when filling my axles on XJ and didn't account for the locker taking up space and reducing volume capacity. When installing axle use small amount of clean oil on rubber part of seal and small amount of rtv sealant to seal to axle housing. Also use a caliper and verify that the axle and seal are the right size.