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This happened about a month (800 miles) after a gear install. The thing just blew out! Anyone have any ideas why? Nothing was mechanically wrong with the rear, all parts are in perfect shape (minus the seal of course). Could my rear end vent be too small for the added pressure (higher speeds = higher temps = higher pressure?) after going from a 3.27 to a 4.10? Has anyone else had this problem?
 

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I just got done replacing mine, and I've had my 4.10s in for almost 15K miles. If you have a driveline vibration, as I did for some time, that could cause the seal to wear quicker.
 

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Did the seal melt or just start leaking. If it didn't melt (typically will require 35+ minute high speed track sessions) then the seal was probably nicked during half-shaft de/reinstall. Doesn't take much to damage the seal.

I've had 4.10's in for 40,000 plus miles with no issues. Only time I've ever had a problem was after a 45 minute road race (course) session.

John
 
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