alright. so my front axle continues to blow the drivers (long side) axle seal. took it apart today, again. month-old seal is worn off badly on the top. quite sure i didnt mess it up putting the axle in.

this would suggest that the knuckle is too high on the axle. i dont have the special tool for centering the knuckle, but i did measure the best i could with a set of calipers. knuckle seems centered, if anything, it is actually LOW.

now. the birfield is a bit tight coming in and out of the axle. starting to think the housing is bent. however:
my alignment is all in spec.
axle shows absolutly no signs of damage.
camber on drivers side is actually slightly positive, which is not consistant with bending from jumping the truck etc.

so basicly, do i really need the SST to center the knuckle correctly? ive never ever seen anyone use it setting up an axle. or is it probable that my housing is bent?

quite frustrated.
any input is appreciated. thanks.

I am going to say your housing is bent and that will cause the seal to go out prematurely.

As far as using the SST to set it up, no, you do not need it but it is sure nice to know the front end is set up to factory specs... For nine years I did not use one, the last time I set up my front end, I was able to get my hands on one and it is nice to know that it is set up right. Someday I may pony up the bucks and buy my own.

damn. was hoping that wasnt it.
guess i gotta start lookin for another housing, and buy some more diff armor. blah.