This study addressed the impact of rod surface topography in contact with reciprocating seals. Rods were tooled with and without centreless grinding. All rods tooled with centreless grinding were fluid-proof, in contrast to rods tooled without centreless grinding that either had leaks or were fluid-proof. A method was developed to analyse the machining signature, and the software Mesrug™ was used in order to discriminate roughness parameters that can be used to characterize the sealing functionality. According to this surface roughness analysis, a fluid-proof rod tooled without centreless grinding presents aperiodic large plateaus, and the relevant roughness parameter for characterizing the sealing functionality is the density of summits SDS. Increasing the density of summits counteracts leakage, which may be because motif decomposition integrates three topographical components: circularity (perpendicular long-wave roughness), longitudinal waviness, and roughness thanks to the Wolf pruning algorithm. A 3D analytical contact model was applied to analyse the contact area of each type of sample with the seal surface. This model provides a leakage probability, and the results were consistent with the interpretation of the topographical analysis.