Front Differential replacement

[rjohnson]

Can anybody help me with the directions for replacing a front differential on a 1996 explorer xlt 4x4 automatic?

 

[my pos mounty]

Assuming you want to remove the entire front differential/axle assembly:

Loosen axle nuts on both sides
Jack up truck, put on jackstands
remove front wheels/tires/brakes/rotors
loosen the bolts on the diff cover that you can, jam a screwdriver in there to open it up and drain fluid
loosen/remove pinch bolt on upper control arm/ball joint-take balljoint post out of knuckle
loosen castle nut on lower ball joint
loosen castle nut on tierod end, remove tierod from knuckle
whack knuckle with a BFH near where lower balljoint goes thru, once it drops, remove castle nut and knuckle
remove cv/axle from diff by inserting screwdriver between inner flange and the front diff and prying it out
repeat all steps for the other side
get under truck, loosen and remove the 3 bolts that hold the front diff to frame


Install is reverse of removal

 

[explorerguy89]

that makes it sound all nice and easy =p

 

[my pos mounty]

that makes it sound all nice and easy =p

It kinda is easy once you do it a few times

OOOPS:

Forgot to mention that when you go to hang the replacement under there:

1) You will want to have that diff cover already in place and sealed with RTV sealant. You will not be able to put it on once it is installed in the truck.

2) Take out the fill plug before hanging the replacement under the truck too, it really sux if you can't get it out and its already in the truck.

 

[ahodges]

as a side note to my pos mounty, you don't have to remove the whole hub assembly. If you follow all the directions above minus any work on the lower ball joint, the half shafts can still be removed, its just not as easy and it puts strain on the CV joints. Just a thought. I've done it this way a few times now and its possible. I just got done replacing my front differential carrier unit..

 

[my pos mounty]

ahodges:
I knew that that was possible, but like you said, it does put strain on them and I had visions of pushing all the grease to one side and then it would not work its way back into the joint. Resulting in the axles untimely death at the most inopportune moment.
You would have to understand how my luck has been going with my truck to understand my mindset when I work on it. It really defies description and you wouldn't believe it if I told you all of it.

 

[techieman33]

The only thing I break free is the upper control arm, the axle will come out it you play with the steering wheel a little. I don't think it puts much stress on them, and any grease that gets displaced will be re-distributed very quickly from the centrifugal force when the axle spinning when your driving it.

 

[ahodges]

ahodges:
I knew that that was possible, but like you said, it does put strain on them and I had visions of pushing all the grease to one side and then it would not work its way back into the joint. Resulting in the axles untimely death at the most inopportune moment.
You would have to understand how my luck has been going with my truck to understand my mindset when I work on it. It really defies description and you wouldn't believe it if I told you all of it.

Oh i understand, I think I read one of your threads about all the problems you've had. That's unfortunate

 

[techieman33]

I would also plan on it taking T least a day for your first time. If you get good at it it can be done in a couple of hours with just hand tools.