Front end probs

[Tanya Phelps]

I have a 03 Explorer AWD that has had 2 front ends put in it...Before the first when you turned it would act like the brakes were on and I would have to give it gas to move and there was a popping noise like CV axle going out eventually the front end went out and had to replace it...it ran good for about 3 months then started popping again so we replaced it again along with CV axles..when testing it it did good for about 20 min then literally threw the axle seal...help

 

[FR-425]

Sounds to me like the differential housing is cracked.

When power is applied the ring gear is pushing away from the pinion causing a sever misalignment pushing against the axle shaft moving it off-center and popped the seal out. Not to long before something breaks with this going on.

I suppose it is possible this was missed on both rebuilds.

I have no doubt something is way out of alignment or is just not secured properly on this one.

Missing bolts or rivets on the chassis for example, allowing the whole assembly to move.

Did you just buy it? Any crash damage?

 

[Tanya Phelps]

No leaks before our after in the housing...fluid was checked in the first one about 30 minutes before it failed while I was driving it

 

[FR-425]

Ok.

I agree we are not talking about a lubrication failure here.

I was thinking along the lines that the bosses inside that the bearing caps bolt to have failed, either broken or the threads may have pulled out. This would not result in a leak.

For sure you have a leak now that the seal has popped out.

It's entirely possible whoever put this thing together keeps doing it wrong and the differential is being assembled incorrectly.

Obviously something is majorly wrong with the way this thing is assembled.

 

[FR-425]

Anybody got any other ideas on this self terminating front differential?

Oh stupid me. AWD!

Different size tires are a big NO NO an All Wheel Drive models.


If you have different rotation speed due to mismatched tires it will overheat and destroy differentials and the transfer case.

CHECK YOUR TIRES TO BE SURE YOU DON'T HAVE A SIZE DIFFERENCE SIDE TO SIDE-FRONT TO REAR. ALL MUST BE THE SAME.

Always replace all four tires at the same time and have them rotated at each oil change.

 

[Herbie 5.0]

if the front end is binding and breaking it could be a transfer case issue, maybe the viscous coupler has seized. the case is where it is designed to slip in an awd vehicle and if its not doing its job it will cause binding in the entire system with the front being your weak link. I hope this helps some.

 

[Tanya Phelps]

Herbie 5.0 you are the 5th person to tell me.that ...does that require a transfer case rebuild or can that coupler be replaced do you know

 

[my02mounty]

Tanya, I'm having the same problem with my 02 awd mounty. Can someone point us to a transfer case replacement how to thread?

 

[Tanya Phelps]

My02Mounty
Is that what you were told would fix yours???

 

[my02mounty]

My02Mounty
Is that what you were told would fix yours???

Yes

 

[Tanya Phelps]

We are replacing the transfer case ANOTHER front differential axles and rack and pinion because of warped tie rods when the axle came out...fingers crossed

 

[Tanya Phelps]

We are replacing the transfer case ANOTHER front differential axles and rack and pinion because of warped tie rods when the axle came out...fingers crossed