Front Differentail Vent Tube Cap Melted??

[MSM0075]

I took a two hour drive in my wifes '02 Mountaineer 4.6AWD for some training class' for work.

On way back smelt something nasty like gear oil. few minutes later smoke was comming from behind.

Pulled over, found out the front differentail drivers side output shaft seal blew out, causing loss of gear fluid.

Upon inspecting vent tube found that upper vent cap was burt/melted. lower plastic was intact. Tube assembly was in the stock location. Not touching or rubbing on anything.

The main question is. Was it melted due to lack of ventalation or was it melted to begin with..

Even with the burt vent tip it was not covering the whole completly to not allow air to escape.

Does the differentail 'gasket' look factory??
Im just curious to see if its been serviced before.

Vehicle has 41k miles on it.

Only other problem I've been having with this car is it choppes/locks while turning tight at slow speeds
Judging by the TSB's i'm guessing its the rear clutch pack. This problem has been going on since we've bought it at 32k miles.
I just thought it was an AWD thing..

 

[EasyRhino]

my guess from here, if I understand your data, is that the melted part is the result of extremely high temps. in the differential, due to running near dry or low on fluid. I think you had the leak first then the heat up then the melted part.

 

[MSM0075]

my guess from here, if I understand your data, is that the melted part is the result of extremely high temps. in the differential, due to running near dry or low on fluid. I think you had the leak first then the heat up then the melted part.

Fluid level was fine before. There were NO leaks on this vehicle ANYWHERE before I took it on the trip to PA (from NJ) When I entered PA thats when I smelt it. When I left is when the seal popped out. My guess is that the vent was cloged and caused pressure to build up in the diff and caused the inner seal to blow out. But why was the vent melted...Was it before or after I lost the fluid...


Lets just say...even if the leak accured on the way to PA (when i smelt it) Only a little leaked out. but enough to cause the front diff to heat up and burn top cap of vent.

Both parts of the vent are plastic, only the top cap melted. thats what so weird.

Why would the seal come out? The seal is in great shape all around, even after all of this.

Thats why I WANT to say the vent was cloged, causing the seal to blow out...

 

[MSM0075]

Any other inputs?

 

[MSM0075]

Was unable to install new seal beacuse it seems the bearing has been pushed out too. You can see in the pictures. I can't tap it back in. Now I need to figure what exactly happend in the differentail.....I'm stumped

 

[MSM0075]

Was able to tap bearing back in, Took some efford to get it to move where I wanted it.

 

[MSM0075]

Was able to tap bearing back in, Took some efford to get it to move where I wanted it.

Does anyone have a diagram or picture of where the drivers side front bearing should sit inside of the differentail housing?? There is plenty of room where it 'could' be. I just want to make sure. Ford Parts diagrams where no help on position.

Is it a common problem for the axle seal to blow out on these?
Like I said. I had no leaks before this incident and the car only has 41k miles....all original parts, no mods.

 

[MSM0075]

Any other inputs or wild guess's would be great.

I'm still stumped on HOW this happend....HOW the bearing could have shifted itself.

 

[MSM0075]

http://www.explorerforum.com/forums//showthread.php?t=265632&page=3

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