TOO MUCH TRAVEL IN FRONT SUSPENSION!

Okay here is the problem or advantage, you tell me. I call it both, because if you never lift both tires off the ground, It's not a problem. But with both tires off the ground, suspension at full droop on bith sides, The passenger side axle does not compress enough. I figured this out when the mechanic at 4 wheel parts couldn't get the passenger side axle shaft back in far enough to replace the spindle.

Now if your thinking its the locker, its not. When I pulled it apart to replace the diff case, the c-clipped axle was right up against the center pin of the carier. After the locker install, It was in the same place and you could also clearly see the axle seal was hitting the axle in the same place. By using a comalong, we compressed the dricerside suspension and the passenger side spindle went right on.

However, this does not cure the problem. The stress is still going to be there on the spindle or the axle shaft itself and u-joints. Since I never plan to have both sides in the air at the same time, I don't see it as a big problem, but it does put unneccecary stress on the components.

We have decided to cut the c-clip flange off the axle and see where that puts it. By putting a spring in the flex joint, it will keep both sides of the axle pushed out enough to keep it from sliding out of the diff. This will give me about a 1/4 inch at the axle housing and about 1/2 an inch at the spindle which is just about what I need.

If you have longer than stock springs, you might want to check and make sure this isn't happening to you. Could be another Superlift 5.5" lift flaw too.

Okay, here is why it happens. As the suspension droops, due to the design, the tires, spindles, and the outer parts of the TTB's get closer together. Basic arch geometry with a stationary pivot point. The drivers side is not effected since there is no pivot point between the diff and the rotor besides the steering nuckle. On the passenger side, you have a deffinate difference in space between the two wheel and the diff when the suspension droops.

Little help here

Does this sound right or am I just making excuses to get my truck back? Please respond if you have aby thought on this.

I need my truck back. I don't know how you did it for so long Rick? Its only been 4 days at the shop for me and I am having withdralls.

bump

Did you change the seal on the outside of the axle assembly? Two different seals are used in the Explorer I'm not sure what your the split is, but I know the '91 is different than the '93. How do I know? I tried to put in a '91 axle shaft complete with it's original seal it did just what you are describing I couldn't push the shaft far enough into the pumpkin to bolt on the spindle. So I swapped the seal for the one that was on my '93 axle and voila' it fit no problem.

The diff case came off a 94 Explorer and I replaced both seals w/ new ones for a 93. The old ones from each diff case and the new ones are all identicle. It is deffinately not the seal since the axle was test fitted prior to putting the diff back in and it was flush against the center pin of the carrier.

I think this is a problem that everyone has, but it is nothing that causes any serious reprocutions. As I recall, when I replaced my coils, I did them one at a time, jacking up one side of the truck at a time, and they fell right out. When I did the ball joints and replacement of the TTB, both sides were jacked up and deooping.When I went to pull the passenger side coil off, I had to fight with it and put all my weight on the hub to get it off.

I don't think this hurts anything unless you are drooping both sides at the same time. This is rare and when it does happen it is usually at such a slow speed that it is not going to have any adverse affect on the suspension. Even if it was at a fast speed,like a jump, the agular motion of the axles is much slower and probably makes the proble unnoticable to us.

The seal I'm talking about seals against the brake rotor and it's on the outside of the axle not the diff housing.

That seal is called the inner spindle seal. It goes against the back of the spindle and on to the outer end of the axle shaft. Picked that one up also for a 93 from Ford since the old one was split. It too is identicle to the removed one.

Yeah, that's the one. Do you still have the old one? The difference is super subtle.

Shafted ??

Another thing to check would be the slip joint on the passengers side shaft as well. I had the opposite problem with mine... The retainer for the boot over the splines split allowing the shaft to compress but not extend. It is possible that if the splines are damaged that It will not allow the shaft to compress. If you pull the boot, please remember to reinstall some form of clamp to hold the boot in place. My 91 was pretty much trail only so I just used Stainless hose clamps.

Good luck

Problem solved and the trucks back home!

We cut the c-clip stub off the axle just before the splines. It was only a 1/4 inch inside the axle housing, but it translated to the 1/2 inch we needed at the other end. Go figure, geometry I guess. It drives straight, and locks up when I want it to in the rear and is always locked in front in 4wd. It makes it hard to steer, but that is where the push button comes in and I just go out of 4wd for tight turns and engage it for the harry stuff. My cheap version of a selectable front locker. I plan to use an ARB when I eventually do the solid front axle.