My green bearings lasted through 12 or 15 years of street driving and drag racing before I had one start to make a little noise. I wouldn't sweat driving them on the street.

I always ran inner axle seals on my 8.75 but on the Dana I just built the moser housing ends don't set the seal deep enough to fit, i guess I will find out how much impact the seal has on bearing life.

Is your axle tube vent clogged? A clogged vent plus heat is the only thing I could think of that could create pressure buildup inside the housing to push the axle bearing grease out like that.

Good thought, I'll check it out.
I installed another center section i had(4.30 w/ clutch sure-grip), cleaned everything up,put the axles back in and took it for a ride. Everything sounded good, noise gone. I will drive it a bit and check the axles again, but rite now they seem fine.