I've got an older Dura Ace (74xx series) hub set I got used over a year ago and built a set of wheels around. They've always spun smoothly. A few weeks back I noticed a bit of a "squeak" and figured it was about time I repacked the bearings.
Following best practices from ParkTool and Sheldon Brown, I cleaned the cones, races and balls - all look good without pits. I'd tightened things up and rode the bike about 50 miles. I noticed Phil Wood grease leaking out from the cone on the non-drive side (the side I broke loose). So I opened up the cone, packed in more grease and got it much tighter this time, but not so tight it didn't spin smooth.
Now I've got almost 100 miles and this morning I see grease again. I'm pretty sure I can't safely get this much tighter without affecting compressing the bearings.
Do I need a new cone or rubber seal? The rubber o-ring/gasket flops a bit, but is not torn.
Did I just put way too much grease in there? (is it possible to do this?)
I've repacked MTB style bearing before and never had this issue. Any help is appreciated.