Need help replacing front differential

[bobotron]

Hey all -

I am new here because I am desparate for some good advice.

I regularly pull a 4,000 lb. camper with our 98 explorer 5.0 AWD, and things have been going well for about two years now, but now I am getting a terrible whine when pulling under load. And occasionally the OD light would blink.

A local shop said it's my front differential, and that it was almost empty from leaking. So we filled it up, and it didn't help the noise.

So first I guess I need to make sure you all think it is the differential. And second, what are some good options to fix the problem? They suggested I just get a rebuilt front diff. and replace it.

But I thought I would ask here if there is any other route I should consider, like swapping for another axle...replacing the gears myself...swapping to switchable 2/4wd...etc. Or maybe there are some other affordable things I should do while I have everything apart down there. I don't want to spend a ton of money on this unless there is a good reason to.

Anything I can do to help beef up the pulling power of this thing while I am down there will be considered as well.

Thanks in advance.

 

[Turdle]

Hi--and welcome to the site
I'm sure there will be other opinions-but I am stumped as to why a front differential fault could possibly trigger a transmission code (flashing OD light).

There is a way to have the vehicle scanned for service codes-which I am sure are stored in the non volitile memory of the PCM.

If you have a laptop-I strongly urge you to consider investing in a scanning device--they can be had for as little as 60.00, and the software is free

www.scantool.net

^^^^that one will retrieve the hidden, or stored faults

I don't think the freebie scanners at autozone or O'reilly's have the capabilty to retrieve the hidden faults-but I may be mistaken on this. You might need to go to a dealership, or a shop which has a good scanning device.

 

[bobotron]

Good point. I have an OBDII scanner I got for my Jetta. I will hook that up and see what it says.

 

[bobotron]

Well I tried my scanner and it said no codes. I went to Auto Zone and theirs said no codes as well. So I am not sure where to go from here.

So if I need a new differential.. is it worth rebuilding? Or is it going to be less to purchase a junkyard axle or a rebuilt one or something? Or maybe I can convert to a switchable 2/4WD system?

 

[MountaineerGreen]

The front diff would most easily be swapped out with a junkyard unit. Your ratio should be easy to find (3.73). I wouldn't pay over $200 for a lower mileage one.

As for your flashing light, I am with jtsmith- a diff gone south shouldn't make your OD light flash. That usually indicates a transmission problem. You may have to go to a stealership to have the transmission codes pulled.

Your diff still needs to be replaced or repaired as well, regardless of what you do with your trans.

 

[Hokie]

The front diff would most easily be swapped out with a junkyard unit. Your ratio should be easy to find (3.73). I wouldn't pay over $200 for a lower mileage one.

Print out the instructions on this thread:
http://www.explorerforum.com/forums/showthread.php?t=53863&highlight=front+diff

It will help tremendously! I have pulled the '95-2001 front IFS diff 3 times now. The first time I did it in 45 minutes and now, if I have all of my tools layed out, I can do it in about 25. Its really not that hard. You only have to jack up the passenger's side wheel. Once you remove the brakes and passenger's side CV there are only three bolts holding it in. Getting it back in will require the use of a good floor jack and usually a buddy to help you guide it in (unless you're MountaineerGreen who seems to have unGodly strenth and can man handle it in himself ) I can easily do it in under an hour with help.

Putting the CV's back into the diff takes a little practice as you will need to get the circlip to line up, otherwise it will block the splines from going in completely.

I'll ask others to chime in there, but would putting a little Vaseline (Petroleum jelly) on it to temporarily hold the circlip in place hurt anything? I would think it would dissolve in the gear oil and not affect anything?

 

[bobotron]

OK thanks. That sounds like a plan. $200 is better than I was expecting.

The front differential fluid was over a qt. low, so it seems reasonable that it has problems regardless. I refilled it and havent seen the light come back on, but whine did not improve.

Like I said, I have been pulling a heavy camper for a couple years now. Hopefully the tranny isn't going south as well. I always tow with OD off, but now it is starting to act strange sometimes... like when I start going up a big hill, it doesn't want to accellerate in third gear. It kinda "shudders" the whole truck when I ease on the gas and doesn't want to drop back down in to 2nd.

So hopefully this so-so weekend mechanic can find a replacement and drop it in this weekend. :-\

Thanks for the help all.

 

[Hokie]

So hopefully this so-so weekend mechanic can find a replacement and drop it in this weekend. :-\

Easily done in a weekend - let us know if you need help during

 

[MountaineerGreen]

Have you serviced your transmission recently?

I can do a diff drop and reinstall in under 2 hours.

 

[bobotron]

No I have not. What all would that entail? Just a flush?

$70-$100 sounds like a lot to me to flush and replace the fluid. Should I pay to have this done, or can I vacuum it out with something and refill it myself?

 

[Hokie]

No I have not. What all would that entail? Just a flush?

$70-$100 sounds like a lot to me to flush and replace the fluid. Should I pay to have this done, or can I vacuum it out with something and refill it myself?

Well, if they actually do a "power flush" then its worth the money. They hook it up to a machine that flushes the old fluid out and leaves only new, clean fluid. Much better than a standard pan drop, drain, refill.

I think Ford recommends servicing your tranny every 30k. I would probably mix a flush or two within the normal drain/refill servicing schedule.