Good point. I meant by the helms with a in/lbs wrench for turning force. My point was that if you torque it corectlly you can skip spacing everything back out. I wasn't so much suggesting he go at it, more that it was an easy fix for a specialist. -1 for me being vague.

 

Right, I know for sure that the nut holding the pinion is not rated at ft/lbs, but more so on it's turning ability. Should be a slight resist from what I was advised. Going to inspect the diff today and check it out. Thanks guys .

Special thanks to PuddyDad

 

Okay so diff turned out to be good. It's only leaking because of that companion flange moves back and forth.

The nut was never replaced. Now that flange is not something that should be moving is it? When it's fully extended out, I can BARELY see the rubber boot underneath.

 

It shouldn't slide in and out at all.

 

Got it, looks like the nut needs replacing then. May as well replace the seal on the inside since it's been flexing.

 

Anyone know how to replace that oil seal? Seems it's attached to the gold area. Thanks guys!

 

If only it was gold

The "gold" is the thin metal sleeve, with the rubber seal vulcanized to it.

First find a tube - not too thick walled, or something simular - to slide over the pinion splines to avoid damage to it.
Then use a screwdriver - or a proper small chisel - to break the front of the metal sleve.
Chisel from out to in - hitting the pinion protector, if you know what I mean.
Then use pointy nose pliers to "wind-up" the metal sleeve, just like you open a tin of sardines.
The metal sleeve is pretty thin and will tear once you have a cut.
As soon as the metal sleeve is - partly - broken you should be able to pull the seal out.

There are official seal pullers too.
Most are just a hook, but with the pinion still there I don't think they work.
Then you got the cork-screw type seal puller but I don't know you have enough material to get grip.

Be VERY CAREFULL not to damage the bore your new seal has to go in.

 

Got it! I just got the service manual for it and was a little confused. Looking at the diagram, it made it seem as if the rubber and gold colored metal were 2 different parts although they are binded. I was afraid of damaging that part. Just took a screwdriver and covered the pinion splines and used some elbow grease and it popped off.

Got the new oil seal, going to snap it on today and install the diff this weekend. Kind of excited for the 4.77's! Will post an update later this weekend!