[RedBarchetta]

Bob, I had a similar occurrence on the driver's side inner. What was happening was when the axle traveled to its lowest point (rebound after hitting a bump), it would tap the frame. This didn't cause a tear, but it effectively loosened the steel strap just enough to eject grease all over that triangular section of the rear frame members.

I ended up doing a couple things. First I pulled the half-shaft and had it re-packed and a new band installed. I then modified the rear differential brace to essentially move the axles up into the triangular frame about 1/2" more. See my gallery for a pic of this. That slight movement added some additional clearance without upsetting the pinion/drive shaft angle.

As additional insurance, I took a thin smear of Black Ultra Permatex sealant and layed it between the boot and steel "can" (for lack of a better term) along the entire circumference. No more leaks.

-Dean #747