I have the D60 up frot in my truck. The right axle seal has started leaking.
I pulled it apart today to replace the seal, well I pulled the axle shaft and realized the carrier hs to be dropped out the center.
How stupid is that?

Looking at the design is there a kit to improve the seal, or add an outer seal?

Replacing seal, okay that will stop the leak, but anytime you run in mud, sand, or snow that tube will fill up and keep woking and destroying the seal.
I can't imagine that entire shaft does not have any outer support if there is any movement in the u-joint at all, that shaft will tear the seal out.

Somebody has to make a retro kit, and you guys know everything so where do I go now??

nope, you have the design, and thats how it works. the tubes always fill up with crap. i have seen thick rubber fit onto the end of the axle tube and rides on the axleshaft as a kinda half assed extra seal.

you could always try filling your tubes with the spray foam insluation to see if that works?

I think I could stuff a lip seal in out there on the end, maybe even put a bearing out there.

Just have to decide If I am motivated enough. The last set of seals lasted 106K miles, How many will this set make??
Since I am doing it for myself and not someone else, probably 2k.

Exapanding foam? Hmmm! that's not a bad idea, it would keep the tube clear.

me thinks the shaft would wallow out the foam and open up just enough to let crap in and not out. besides, have you ever tried to clean that dried foam off of something? not pretty.

when you change your fluids you're better off blowing them out from the carrier side out to the knuckles.

i was sorta kidding, but am kinda curious if it would work. If it wouldnt, it would be hard to get out

if you could keep it from getting old, hard and breaking down :shrug

I am wondering if the seal gets flat from sitting. I haven't used the 4x4 since last winter.
I pulled the shaft and the axle seal surface looks great, I wonder if I lock it in, and warm the seal up a little by running it, maybe it will seal up again?

With all the reading I have doing about these, it is not very often I see where someone has had to replace them.