1999 explorer limited v8 awd differential | Ford Explorer Forums

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1999 explorer limited v8 awd differential

Joined
February 25, 2010
Messages
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City, State
Pittsburgh Pa.
Year, Model & Trim Level
1999 v8 Limited AWD
So I need to get the front diff replaced in my 99 limited awd(v8 5.0)and am totally lost. Anyone have any experience with this? Its pretty expensive because I was told that I should replace the housing as well. Any idea where I could even find the parts at a somewhat fair price? I could really use some help. This is a new 1 to me.
 



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You want the whole front differential and axle housing? Try www.car-part.com and find one in a junkyard close to you, if you want to go that route. (should run around $130 or so)
(EDIT: The name of the item for car-part purposes is "carrier (see also differential)"
To remove the entire front axle assembly:

Jack up the truck, put on jackstands so the front is in the air

Take front tires off

Have someone hold the brake, loosen axle nut on both sides

remove brakes and hardware, hang calipers from a piece of wire, dont use the hose for hanging purposes

Remove the "thru bolt" from upper control arm

Seperate upper control arm from steering knuckle

Remove cotter pin and remove the nut on the tierod, remove tierod from steering knuckle

Remove the cotter pin from lower balljoint, loosen nut almost to the point of taking it off

hit the steering knuckle right around the area of lower balljoint, knuckle should drop down to the balljoint nut, remove it and knuckle while pushing the CV inwards

Use a long screwdriver, insert screwdriver between the inner CV flange and the front differential and pry it out, it will come out easily if this is done properly. Diff fluid will come out of the open end of the diff/axle assembly. Don't worry about that, is junk anyway

Repeat the above steps for the other side. I took out whatever front diff cover bolts i could and inserted a screwdriver to make some space to drain the diff fluid.

Climb under the truck, there are 3 mounting points (edit, or are there only 2?hmmm) for the entire front axle assembly, remove the nuts and bolts (the nut end has a "keeper" of sorts on it to help).
The whole assembly is about 60lbs. (im guessing) so be aware of that, its not overly heavy, just awkward.

Replacement is reverse of extraction.

Before you replace the front differential and assembly (if going with the junkyard one) make sure you can remove the fill plug (wont do much good to hang it under the truck if you cant fill it) replace the axle seals (easy job now, really sucks when installed) and take a good hard look at the outer axle bearings that the CV shaft ride on (again, a heck of alot easier to do this now with the assembly out of the truck). This is where it may be best to rebuild yours, but that decision is yours and should depend on why you are thinking of replacing the entire assembly.

Does this answer your question?
There are also some members that have the assembly for sale, check the "auto parts for sale" area
 






OH forgot to say something

You will (of course) need to know your gear ratio. Theres a sticker on the drivers door, on it under the heading of "axle" is a code. The codes and corresponding ratio is listed below as well as open or limited slip. You will not have a limited slip in the front carrier, so all you need to know is the ratio.



Explorer Door Codes:

41..... Open 8.8"…...... 3.27
42..... Open 8.8".…..... 4.10
43..... Open 8.8"…...... 3.08
44..... Open 8.8"…...... 3.73
45..... Open 8.8".…..... 3.55
46..... Open 8.8".…..... 3.73
D1..... L/S 8.8".…....... 3.27
D2..... L/S 8.8".…....... 4.10
D4..... L/S 8.8".…....... 3.73
D5..... L/S 8.8".…....... 3.73
 






Thanks my pos mounty. That actually made things alot clearer for me. Greatly appreciated.
 






Well apparently my explorer limited has a dana super 30 in it and the front diff was totally destroyed. So I just shelled out $1275 for a whole new unit/install. Oh well, 1 less thing I have to worry about breaking. Out of curiousity do you know what is in the rear? Is it a Dana 44 like I think? It is a 99 limited awd 5.0. Hopefully I will have it back today.
 






Well apparently my explorer limited has a dana super 30 in it and the front diff was totally destroyed. So I just shelled out $1275 for a whole new unit/install. Oh well, 1 less thing I have to worry about breaking. Out of curiousity do you know what is in the rear? Is it a Dana 44 like I think? It is a 99 limited awd 5.0. Hopefully I will have it back today.

The rear axle is a Ford made unit, 8.8 inch ring gear, 31 spline. If you have the "Limited slip" Ford refers to that as a "traction-lok"
 






Make sure you get the same gear ratio!

I know its common sense, just figured I'd throw it out there since no one else had yet. :)
 






The front diff is the same in AWD's and 4WD. There is probably a dozen or so in the local junk yards.....
 






Uhmmm, he just dropped almost 1300 to have the front replaced. At that cost the shop had better have known the right ratio, taken him out to dinner and kissed him on the cheek at the end of the night.
 






Uhmmm, he just dropped almost 1300 to have the front replaced. At that cost the shop had better have known the right ratio, taken him out to dinner and kissed him on the cheek at the end of the night.

well put.

at the dealership i work at ive seen much stranger things happen. like the customer that brings their chevy trailblazer back a little while after the same repair with a destroyed front ring and pinion. parts guy forgot to check to make sure it was the right one.
 






Ford garage wanted $2400... As far as the junkyard thing I thought about it. I just wanted to put new parts in it and be done with it. As far as the ratio goes they better get it right. This is my primary vehicle and I have a job depending on it. They are a fairly well known transmission shop here in the Pittsburgh area. Been around for a long time. They also do race mods. I replaced the housing and everything that goes along with it.
 






What goes wrong with them ? Bearings and junk ?
Probably the same issues the alum 8.8 irs diff in the Gen 3's has ?

Pittsburgh Rick, what miles is your rig @ ?

That 8.8 out back is a tried and true durable piece and probably still being used in brand new fords.
 






I am looking at 153,000 on the odometer. The shop said the diff was trashed. This is the only problem I have ever really had w/it. I have the worst case of OCD on the planet when it comes to maintenance to say the least. It runs great and the interior/exterior is spotless. Ive had alot of offers to buy it from me. I have a flowmaster 40 on it, a superlift add a leaf in the rear, K&N, and the normal maintenance. Ford garage said it seems to have as much if not more power now than it was rated at when new. I dunno. It runs good to say the least for the minimal mods I have done.
 






what goes wrong with it? its a Dana 35... enough said

they all have issues, solid axle of IFS

mines crappin out too, but hopefully I'll be SASing when it finally gives
 






I would be seriously questioning that shop as to why they think you have a Dana "super 30" under your truck (unless you mis-understood what they said). Its an IFS Dana 35 as stated earlier. If you are as much of an OCD personality as you say, you should be climbing up their butts and watch their every move. I would want the receipt and the shipping container (or box) from whomever they bought this "brand new" unit from so I would know it wasn't from Jacks Used Auto Parts. Tell them you want your old differential packed in the container/box the "new" one came in.
 






I agree with Mounty- check every move they make, lots of places are popping in used, painted parts and passing them off as new...
 






I was actually up there the day the part was in. They diagnosed it awhile ago. Yes the part is new. As far as going up there its over an hr outside Pittsburgh and if ya read my previous reply this is my primary vehicle so going up there would be kind of a long walk. I don't know much about this stuff so I prolly misunderstood them. I know the basic stuff. I did learn alot of stuff from my cousin though by playing around his 66 goat. He did a motor swap from the original 400 to a 502. Thats about all of the knowledge I have when it comes to this stuff. The packaging was there and the reciepts are legit. My cousin introduced me to this shop. He has been riding Harleys with the owner for around 20yrs now so I trust em.
 






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