need to replace rear differential seals 2002

[greeneye]

I'm looking for a how-to thread for replacing read diff output seals.
I have searched high and low with no luck.
My 2002 rear end was replaced 40k miles ago and now at 82k miles the right side is leaking. I bought the parts: 75w-140 full syn, friction mod, and the seals - total was $30. I want to fix this myself. Dealer price estimates for 1 side repair ranges form $250 to $325. Two sides costs $350-$425. Prices are P&L, and they vary by dealer here in MN.

Can anyone point me to a how-to thread on rear diff output seals? I would like steps to walk me through everything, especially how to remove the half axle from the diff output socket. I have gotten mixed advice on this - some say that there is an internal retaining clip and others say no. I was hoping not to buy an expensive shop manual. Napa told me that diff seals are probably not covered in your standard haynes or chiltons.

Thanks
Paul

 

[IZwack]

Napa told me that diff seals are probably not covered in your standard haynes or chiltons.

My guess is that it is.

Thread moved to third gen stock forum

 

[greeneye]

Getting ready to replace seals

I bought the stuff and I'm planning to do the seal replacement next weekend.
The Chilton's manual shows most of the steps in good detail as the previous poster suggested. I apparently bought the old style seals, online at rockauto.com, for $4.60 each. These will require some care to onstall. I got 75w-140 full syn at Napa for $13 per quart. Got friction modifier at Ford dealer for $5. Bought a 36mm deep socket and breaker bar for the hub nut, was about $25 at the China tool import store.

I plan to use a pair of thin 14" prybars as wedges to unseat the inside of the half axle from the differential, then I'll tap them out the rest of the way with a big hammer and stick.

If anyone has any experience and suggestions, let em rip. I'm fuzzy on how to get the new seals in and how to put the axle back without ruining the seal.

Paul

 

[djwhoo2005]

God help us all..... I have the same probllem rear axle differential seals leak.. i cant get the axles to pop put.. i called the tech at the dealership. he says i have to crack open the differential pumpkin to get the axles off from the inside out. is that right? if so.. screw it.. to the dealership i will go.

 

[stuartr]

Any update on this? Do you have to open the rear end plate to release the axles? I may need to put one in mine.
STU

 

[2003vstrom]

you don`t have to open the diff to get the half shafts out from the rear end you have to use a pry-bar or similar to get them to pop out, there in there pretty tight but they do come out that way.

 

[stuartr]

Thanks, I am not sure I will have to do it right now.
STU

 

[oversteer]

I have replaced these seals. In order to get the axles out of the diff, I used a 2x2 about 12" long and a small 3lb mini sledge. They pop right out pretty easily. You do not need to take the diff apart. I used a large socket and lightly hammered in the new seal. Hope this helps!

 

[yotadcb]

I am in the process of tearing out a rear differential on a 2002 Eord Explorer. There are retaining clips, one on each shaft. Of course, I have the backing plate off because I didn't have the proper tools to take the nut off the half shafts. I used a wedge(nail puller) to pop one side out. Then I took out the bolt that holds the pin in the middle with the gears on it. Use a long bar or extension to come through the opposite side and drive the other shaft out. It may take a few good wacks. My pinion bearing is damaged pretty good, a lot of free play in it.

 

[aatomicdawg36]

I have a 2002 EXP, XLT - Axle Code 45- which is the Open 3.55. I have a leak in the rear axle pass (right) side and the same in the front pass (right) side. I've looked up part#. As near as I can tell, the rear should take the MOTORCRAFT BRS-40, but the FRONTS take either the BRS-10 or the BRS-31. Does anyone know what is the exact Part # for the front? Or how I can find out which part# my car takes ? THANKS!

 

[aatomicdawg36]

Do you happen to remember the part number your ordered from ROCK AUTO? I'm trying, I'm having the same problem as everyone else here with leaking seals, on the front and the rears, and I'm trying to order the replacement parts. I've ordered from RA before I they are great, however, there are a couple of different parts they carry for the fronts and the parts seem to have different measurements as well, almost as if there is an "inner seal" and an "outer" seal. I can't tell if I need one (or the other) or BOTH?? Thanks if you can help.

 

[roush9799]

WHy do the seals fail so bad on these explorers/mounty's? I've never read about so many leaky seals/rear end problems in any forums before. My pinion seal is leaking on mine. Isn't this basically just the common Ford 8.8 rear end? I've had it in several rangers and mustangs, and never seen so many have leaky seals in those forums as compared to here. I only have 72,000 miles on mine. I'd think I should have gotten over 100,000 before I'd even consider a leaky seal on any other vehicle. The rear gears/bearings should go beyond that. I think I replaced my bearings in my mustang at 130,000 miles for the first time, and none of the seals were leaking.