Testing: I closed off the CO2 and left the setup only with what is in the lines when playing around in my test ditch (deep enough that 2 wheels are in the air and slightly uphill, not do-able without a locker). Crawled 3 times forward, once backwards, no pressure loss in the system. I even left it flexed for a couple of minutes to walk around and listen for leaks.
Never had an issue with mine up to that point either. And I think I was 30 minutes in the struggling when it leaked. Locked all the time, too. Having CO2 instead of air did not help, as once it started leaking, it cooled the o-rings, shrinking them.
As far as I know, in reverse, low pinion rear axles and high-pinion front axles will push the ring gear away from the pinion, causing all sorts of flex in the casing.
http://www.jantz4x4.com/jantz.php?p=...olts&mid=jlbig
I remember seeing load bolts in some other high-end Dana 60's and there's a video from Carl Jantz showing that the ring gear deflection is huge in reverse.
Anyway, it's usually not an issue on the D44a, the ARB is sensitive to it only.
D30's also leak:
https://www.pirate4x4.com/forum/gene...when-bind.html
And I remember some complaining that some Land Rover axles would leak because of case flex.
Moral of the story is, if the line isn't ok the first 3 attempts, try another line....
The leak started after I backed up my rear left wheel up on the bank, so yeah...uphill, reverse, flex. Touch wood the only damage is a scraped rear bumper
https://youtu.be/kjP_DwRWoKA
had mine in for around a year and don't recall any leaking issues while flexed, but haven't gone forward and back very often to get it bound up.
