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Can a 4l60e yolk start leaking ? Mines is leaking and idk if because the yolk is damaged . I replaced the extension housing seal and it still leaking .
Check for slop in the tailshaft bushing. The bushing is easy to replace removing the tailshaft housing, if needed. (eBay)
Drop the driveshaft and inspect the slipyoke for uneven wear on one side. This would indicate a balance problem with the driveshaft. When the pinion u-joint is unbolted bottom-out the slipyoke on the tailshaft and take a measurement. With the shaft installed and weight on the rear axle the slipyoke should only be extended about 1" out from the bottomed-out measurement. Much more than that and the tolerances in the spline allow too much axial misalignment and can cause imbalance. At highway speeds the RPM of the driveshaft is over 2500 and if there's any slop in the slipyoke the seal will not be able to flex fast enough to prevent leakage.
Mine was leaking really bad after my 80e swap in my NBS. After looking over everything, looks like it was a leaky soft plug on the back of the yoke. I RTV'd the **** out of it, and it seems to have solved the issue. Ill be pulling it now and having it welded up, because the RTV is hideous.