Autozone told me they couldn't get one

 

Check other auto stores? Napa? Advance?

 

Ok, so I drop the front half of the D/S. I then start to take off the pinion nut thinking this is going to be a PIA again to take off and to my surprise it came off easy. When installed it the first time I put on the red loctite and tightened to 160 ft lbs. So I have no clue why it was so easy to come off. Then I thought well I will go through the PIA to get the yoke of and it just slide right off, no problems at all. I cleaned up the excess gear oil and thought I would try putting it all back together and tighten it down real good again and apply more loctite. I then checked the front diff and added more gear oil to make sure it was full. Then drove about 25 miles with speeds up to 65 mph. I stopped and checked it twice, just to see if it was leaking and to my surprise it is not leaking as of now.

Could the seal of been leaking due to the pinion nut not being tight?

 

So, it's not leaking now...

But after you torqued the nut to 160 ft/lbs, did you measure the torque to rotate, and if needed, increase the torque on the nut in 5 ft/lb increments until the torque to rotate was 5 in/lbs more than what it was just before you took it apart?

 

Not quite sure what you mean, but I took it up to 166 ft lbs. I wasn't thinking when I first took it apart and didn't mark my axle shaft and pinion nut to make sure when I tightened it back they lined up. That was a lesson learned. I am still going to go ahead and order a new pinion seal and nut just to be safe.

 

Measuring the torque it takes to rotate the pinion, and increasing by 5 in/lbs more than it was before disassembly, ensures the crush sleeve is still doing it's job, and the pinion preload is maintained.

 

The pinion preload is crucial. If it isn't right you could end up with much bigger problems than a leaky axle. I have no idea where your mechanical skills are but if you start hearing or feeling weird stuff from the front axle, take it to a shop. Setting up a diff gear set isn't a job easily done if you don't have the right tools.
As a quick warning...I had an inner pinion bearing on my old CJ fail at 70 mph on the highway. It sent the Jeep into a flat spin and I had no control of the vehicle. The pucker factor was off the meter. Don't end up in that situation. Not fun at all.

 

My front Pinion Seal was leaking also. Took mine in for a routine service on Saturday and they did it for me under warranty even knowing I had 5:13 gears installed. But my dealership is Mod Friendly when another customer has a lift of gearing question they refer them to me for input. I have even met some at the dealer and gave them a ride in my jeep.