Help with filling 1996 Explorer front differential

[markdenisr]

The front differential on my Explorer has the fill plug completely messed up. I just left the mechanics and they tried about everything short of drilling another hole or drilling the existing plug out. I know they could take the complete differential out and then do it, but that would be rather expensive.

So, my question is: is there another way to get fluid in the front differential other than the fill plug?

Actually it is a 1997 Explorer, not a 1996.

 

[my pos mounty]

Hmmmmmmm, only thing i can think of is .. Jack one side of the truck up alot more than the other, remove cvaxle, pour needed lubricant, replace cvaxle, lower truck. Thinkin the mechanic wont be willing to do this, but you never know.

 

[markdenisr]

I don't know if they would try and jack the vehicle up and fill or even if that would work, but I guess I could ask them. Do you or anyone else know if the front pan bolts are in a blind hole or if they go through into the inside of the unit? Maybe I could fill it from one of the upper bolt holes.

 

[corkey]

i would say taking off the drivers side axle is the easiest way, the cover will not come off too easily, and the bolt holes will not flow enough fluid if it is cold,, and than checking the level would be a pain, drivers side axle was how we did mine when Jon and i did the lift kit, as we already had the axle out,

 

[coonerboy]

You could also try the vent tube. Would take forever though and there would really be no way for you to know how much you have in there. The tube ends up on the driver side frame rail in the engine compartment.

 

[my pos mounty]

None of the bolt holes pass thru, so those are not an option. The vent line is rather small, how many hours do you have? I would say the driver side axle would work best if you were going to "tilt" the truck as the passenger has a longer axle tube and thus would be able to get more fluid inside the diff and axle with the least amount of "tilt".

 

[Elessar65]

i would say taking off the drivers side axle is the easiest way, the cover will not come off too easily, and the bolt holes will not flow enough fluid if it is cold,, and than checking the level would be a pain, drivers side axle was how we did mine when Jon and i did the lift kit, as we already had the axle out,

What he said, it takes a while for it to drain out the axle tube though. Have you tried using heat to get it out? How is it messed up? Cross threaded, stripped, broken? Try welding a bent bolt or something to the plug as a handle?

 

[markdenisr]

I think the plug is aluminum. It is completely messed up where nothing will fit it. It appears to be froze solid. It is possible someone used or maybe even cross threaded the wrong type of plug in it. I just bought the Explorer and was in the process of going over everything when I found the problem.

The differential appears to be leaking around the seals a bit and may have been for some time. I can here a slight roar from there while driving. I really think it is low of fluid causing the roar. I might try adding fluid a little at a time down the vent tube if I can find it and see if it helps with the roar.

 

[Elessar65]

If its that messed up you might just try and get a front diff from a junk yard with the same ratio and swap it in. And get a steel plug for it.

 

[my pos mounty]

If its that messed up you might just try and get a front diff from a junk yard with the same ratio and swap it in. And get a steel plug for it.

X2
After the Cash For Clunkers, there are tons of these in the boneyards. I dont know what they run in your area, but where I am I can get the fron diff, with a 90 day warranty for $98.

Check car-part dot com.. for the part enter "carrier"..enter zipcode..select distance..select ratio... VIOLA you have a billion to choose from.

 

[Electrohacker]

or you could do a lift and a SAS, common, you know you want to