HELP- dynamited 02 limited rear driveline

[EHebner]

What I need-

A list of good donor vehicles for the entire rear driveline from driveshaft all the way to hubs.

Specifically how to tell which Mountaineers/Explorers will have a driveline that will work in an 02 limited 4wd V8 and if any years, models, packages have a better driveline.

The Story-

So my wife's Grandparents drive up from Ft. Myers to Tallahassee to take my wife and 2 boys on a 2 and a half week vacation to see our families in RI. I get two and a half weeks to work OT, swap axles in the jeep, go camping with my buds, without a single complaint? Insanely awesome! So, the social security budget grandparents have this 02 Explorer and my GFIL says it has this wobble in the front end on the highway, could I take a look at it?

So I check out the front end, a little play in one of the ball joints nothing major, lets take it for a drive. Notice a lot of 'road noise' maybe bad tires? Get on the highway and take it up to 70, and I say "Well, it sounds like the front, but there is no vibration in the wheel, but I can feel it under my seat, I think the problem is actually in the rear"...5seconds later... boom, vehicle jumps, loud dragging sound, thumping on the bottom of the vehicle, damn we dropped the drive shaft. Get off on the shoulder and yup, driveshaft on the ground he has AAA they will be there in 30.

2 hours later the Explorer is in the driveway. Get under there and DAMN!!!! The U-joint loops on the driveshaft are wallowed out, the U-joint ripped the mounting plate on the diff to pieces, the forward rear diff mounting bolt is sheared off, the driver's side CV is 1.5 inches out of the diff with fluid leaking, massive grease loss from first driver's side CV axle boot, hubs where they connect to lower control arm have 3/8" play looks like bolts may be sheared.

So now the GILs are here to stay until I get this fixed because they sure can't pay a shop to do it and I can do it with junkyard parts, just need to know the right ones.

 

[EHebner]

Ok, so I have 3.73 LS. Anyone know if there are vehicles besides the mountaineer and explorer that ran the same driveline?

 

[r6bikerdave]

no other cars share the same. 02-05 had the same basic setup, only change I am aware of is the abs changed from being 1 sensor on the rear diff....into two individual sensors mounted just behind each rear knuckle. 04-05 had 2 sensors, 02-03 could be either way(depending on stability control). (I have an 02 limited v8, and mine has the single sensor, just for reference)....not even sure if stability control existed in 02-03 explorers

 

[BarryCarey]

Some Lincoln Aviators have the same diff. As far as I'm aware those are the only 3.

I replaced mine in July. Pinion seal blew on the interstate and caused the rear end to run dry at high speed for several miles.

Found one at a junk yard for $250. However, the database system a lot of yards use recommend they sell it for $350

You will also want to get the clips that hold the half shafts in the diff. Should be less than $5 from the dealer.

Good luck getting it all sorted.

 

[EHebner]

What I ended up doing

Thanks for the responses guys. In my own research I found that the Limited slip rear diffs in 02s had a lot of issues so I ended up pulling a regular 3.73 and two cv axles from pick n pull, and got a rear drive shaft with mounts from a recycler. Also did one knuckle and both tie rods. End result is a functional rear end with no abs for under $400.

Notes:

In mid 2002 Ford changed the size of the tie rod ends at the knuckle, make sure you have a compatible knuckle and tie rod.

4x4 driveshaft is a 2 piece 2wd is one piece

for ease of installation, leave the cv axle's cups on the diff and just take the axle and boot off, use thick plastic and zip ties to prevent the cup and the end of the cv from getting dirt in them, re-secure boot with hose clamp.