Broken bolts in front yoke

[4BYDIG]

Hi guys, not quite new here, but first time on since I had this ride, on my 99 mounty, I want to replace the front drive shaft this weekend, but the bolts seem to be broken off in the front yoke, was wondering if anybody knew offhand the thread and pitch and whatnot because I was going to attempt to drill them out and tap the holes, never done this before so I'm not exactly sure if what I'm saying is coming out correctly, but I'm more than confident I can do it, just need to gather the supplies, been dying to get the all wheel drive going since I got it

 

[ZWilson07]

Hi guys, not quite new here, but first time on since I had this ride, on my 99 mounty, I want to replace the front drive shaft this weekend, but the bolts seem to be broken off in the front yoke, was wondering if anybody knew offhand the thread and pitch and whatnot because I was going to attempt to drill them out and tap the holes, never done this before so I'm not exactly sure if what I'm saying is coming out correctly, but I'm more than confident I can do it, just need to gather the supplies, been dying to get the all wheel drive going since I got it

N800594-S100

M12x1.75x27


http://www.amazon.com/Ford-Driveshaft-Bolts-N800594S100-M12X1-75X27-0/dp/B00GK4XGW4


EDIT: That is the rear ones. Let me double check if the front are the same.

 

[albi1cnobi1]

Are you talking about the ones on the axle end or the transfer case end?

 

[ZWilson07]

Are you talking about the ones on the axle end or the transfer case end?

I was presuming he was meaning the axle end, where the yolk bolts to the front diff flange.

 

[4BYDIG]

I was talking bout the ones on the front axel, sorry about that, broken off with none sticking out, was hoping to not have to replace the whole yoke

 

[ZWilson07]

I can't find anything else other then what I posted above. I will have to shoot my parts guy an email for him to double check.

Every manual I have and website doesn't give much info or if it shows the correct bolts, you get no info for it.

 

[4BYDIG]

Thanks guys, I'll pr and wind up buying the universal joint strap kit and then just figure out what I need to drill and tap to

 

[albi1cnobi1]

Yeah, I found them on a couple of Ford sites but like Zwilson07 said no info in the listings. Good luck in your search.

 

[ZWilson07]

Thanks guys, I'll pr and wind up buying the universal joint strap kit and then just figure out what I need to drill and tap to

OK OK "I think" I finally got somewhere here.

I just took this picture of my 2000 Explorer 5.0 AWD. Sorry for the quality but with it being super cold and dark, I did what I could.

Are the bolts you need the smaller bolts that hold the straps over the U joint?

The ones almost right in the middle of this picture of mine?

Also would be 389665-S100?

If so this is the only site I have found so far that shows dimensions for it.

http://www.usallparts.com/catalog/p...t-Retainer-Bolt--Original-.html&XTCsid=2769b1

 

[albi1cnobi1]

OK OK "I think" I finally got somewhere here.


Are the bolts you need the smaller bolts that hold the straps over the U joint?


Also would be 389665-S100?


If so this is the only site I have found so far that shows dimensions for it.

http://www.usallparts.com/catalog/p...t-Retainer-Bolt--Original-.html&XTCsid=2769b1...

YOU are the man! Kudos my friend. I've been searching since I saw this thread, couldn't find anything. Next time I need something I'm going to find you!

 

[ZWilson07]

YOU are the man! Kudos my friend. I've been searching since I saw this thread, couldn't find anything. Next time I need something I'm going to find you!

Thank you, I appreciate the kind words. Unfortunately since our vehicles are over 10 years old now, tons of parts are discontinued and just trying to search for parts and/or pictures is a pain in the ass.

I paid for a michell1diy subscription for my 2000 as well as ordering a service manual cd rom for it which using those along with parts websites and connections, I can usually find things with enough time.

I actually was confused in my head as I was viewing the front yoke actually mounting to a flange for the front diff similar to what rear driveshafts use but on our setups this isn't the case for the front. Which is how I came up with the previous bolts posted earlier in the thread, but at least the numbers are shown for the rear portion of the vehicle as well if anyone ever needs those.


OP one thing I would recommend is trying to weld a nut if theres is enough room to get a weld on the broken bolts. The changes of perfectly drilling them out and tapping the front yoke are probably pretty slim. Even if you do pull it off, it probably won't hold for the next few times you need to do service. So I would try the weld a nut route first. Not to mention if you don't drill and tap perfectly, you are gonna have to change out the yoke, pinion nut, etc anyways.

 

[4BYDIG]

Yea, the ones in the middle in the differential side. My front shaft was removed before I got it and they are broken off in there, you guys are awesome, now to figure out how-to fix this situation

 

[4BYDIG]

Thank you, I appreciate the kind words. Unfortunately since our vehicles are over 10 years old now, tons of parts are discontinued and just trying to search for parts and/or pictures is a pain in the ass.

I paid for a michell1diy subscription for my 2000 as well as ordering a service manual cd rom for it which using those along with parts websites and connections, I can usually find things with enough time.

I actually was confused in my head as I was viewing the front yoke actually mounting to a flange for the front diff similar to what rear driveshafts use but on our setups this isn't the case for the front. Which is how I came up with the previous bolts posted earlier in the thread, but at least the numbers are shown for the rear portion of the vehicle as well if anyone ever needs those.


OP one thing I would recommend is trying to weld a nut if theres is enough room to get a weld on the broken bolts. The changes of perfectly drilling them out and tapping the front yoke are probably pretty slim. Even if you do pull it off, it probably won't hold for the next few times you need to do service. So I would try the weld a nut route first. Not to mention if you don't drill and tap perfectly, you are gonna have to change out the yoke, pinion nut, etc anyways.

Dang it, there's nothing to grab a hold to, I plan on regearing this summer, but oh well, is it that bad replacing that yoke? Idk where to even find one, I drive a truck so sometimes it's hsrder for me cause I can't go outside and take a quick look lol

 

[4BYDIG]

Thank you, I appreciate the kind words. Unfortunately since our vehicles are over 10 years old now, tons of parts are discontinued and just trying to search for parts and/or pictures is a pain in the ass.

I paid for a michell1diy subscription for my 2000 as well as ordering a service manual cd rom for it which using those along with parts websites and connections, I can usually find things with enough time.

I actually was confused in my head as I was viewing the front yoke actually mounting to a flange for the front diff similar to what rear driveshafts use but on our setups this isn't the case for the front. Which is how I came up with the previous bolts posted earlier in the thread, but at least the numbers are shown for the rear portion of the vehicle as well if anyone ever needs those.


OP one thing I would recommend is trying to weld a nut if theres is enough room to get a weld on the broken bolts. The changes of perfectly drilling them out and tapping the front yoke are probably pretty slim. Even if you do pull it off, it probably won't hold for the next few times you need to do service. So I would try the weld a nut route first. Not to mention if you don't drill and tap perfectly, you are gonna have to change out the yoke, pinion nut, etc anyways.

 

[ZWilson07]

Dang it, there's nothing to grab a hold to, I plan on regearing this summer, but oh well, is it that bad replacing that yoke? Idk where to even find one, I drive a truck so sometimes it's hsrder for me cause I can't go outside and take a quick look lol

I mean it depends on what your definition of hard is. The crush sleeve that sets the pinion bearing preload, which is crushed and set by that outside pinion nut that you see on the yoke is actually inside the front diff.

So you would have to drop the front diff, pull the carrier and pinion out, and reinstall a new crush sleeve and the assorted items, basically similar to the exact thing you would do for a "proper" front and rear pinion seal replacement. Many have got by with marking the pinion nut, counting the turns, and putting it back exactly where it was with another 1/4 turn, but this can be hit and miss with the used crush sleeve that is still in there. The rear is definitely more friendly when doing that job than the front though as you can just leave the rear diff in and just drop the driveshaft. I am sure you will actually have to remove the whole front diff from the vehicle to get enough room to do all the work.

Your best bet for getting another yoke would probably be just to order a new yoke or of course you could try and find one at a junkyard to pull off somewhere.

The crush sleeve is number 16 in the diagram.

Is there enough of the broken bolts to weld a nut to? Even if it isn't actually sticking out, if the bolts aren't to far down in the yoke, you can still usually get a weld on them. This is really going to be your best bet or have done by someone if you can't do it. If they are able to get those bolts out, you would simply have to just buy the new bolts and strap, and boom good to go.

Versus if you try to drill them out and aren't able to successfully tap the yoke once drilled, then the above which I have already mentioned, will be your plan of action which from personal experience will not be near as fun.

Good luck.

 

[4BYDIG]

Facepalm lol, I'm not looking forward to this, might just have to pay to get one swapped out, reckon I'll order one this week or next week, be home when I get back next time, I been trying to look up that part, but it keeps pukkij and then up for jeeps, not sure if I'm searching right or not, never had this many problems looking up a few "simple" parts

 

[ZWilson07]

Facepalm lol, I'm not looking forward to this, might just have to pay to get one swapped out, reckon I'll order one this week or next week, be home when I get back next time, I been trying to look up that part, but it keeps pukkij and then up for jeeps, not sure if I'm searching right or not, never had this many problems looking up a few "simple" parts

What part are you trying to look up? The yoke/pinion flange for the front diff?

Also just FYI, there is a good chance that the majority of shops that you have that done at, will in fact just do the yoke swap without installing a new crush sleeve. Just marking the nut, counting, and going by "feel." Which again is not the "proper" way but if you are going to go that route, you might as well do it yourself as it isn't to hard going that route.

 

[4BYDIG]

I may do it then, yes, that's what I was trying to find but kept coming across ones for jeep

 

[ZWilson07]

I may do it then, yes, that's what I was trying to find but kept coming across ones for jeep

Thats because we use a Dana35 up front which is used in many applications. Give me some time and I will try and find the actual part number for you. My charts just show 4851 but that doesn't cross over to an actual part number. I dropped one of my connections another email to get the actual part number and double check things, but I won't get that information until tomorrow. You could also just email one of the many companies that come up with front pinion flange parts off google that you see and just ask them which specific model will fit yours instead of the jeep, ranger, etc ones they show.

Also in reference to the bolts/u joint straps from earlier, rockauto is showing that they have them as well.

They show 2 different sizes for the AWD on their site, but the bottom one matches that other site I posted with a 1/4-28 measurement but rockauto doesn't show a length. I assume that maybe the 5/16 setup is for the 4wd setups, not the AWD but I will have to shoot them an email to ask. You'd have to message them about it just to make sure but at least its another option to order from or check with.

 

[4BYDIG]

Man, I really appreciate it, I had found the straps on o Reilly website earlier, can't remember the lengths, checked there and rock auto for the yoke, I have access to an impact and all that, just wasn't quite ready to tear the diff completely down till I'm ready to 're gear this summer. Would like to get awd going, I'm only home like a week out the month, so I normally order everything so it's there when I'm home and just do the work when I get there