When I got home from Car Craft on Friday, gear oil all over, Pinion oil seal is leaking again. I though I had the issue solved; but taking the pinion flange off again today. I thought I did everything right. So I hope it is just the spring coming off the seal or something simple. Could the seal be installed too deep, so the seal doesn't make good contact with the flange shaft? Could a bad pinion bearing cause something like this? Or even worse, is it possible there could be a little crack on the end of the differential housing that is letting oil through? Or maybe the flange is just bad and the diameter is just a bit to small for the seal? Thanks.
Put a repair sleeve on the yoke with sealer and see if that takes care of it. I'm sure you've checked but the vent is working to allow pressure out, right ?