Rear Axle Seal

[Gaff It]

Just had my real axle seal, passenger side, replaced. Was leaking fluid in addition to hearing a low pitched whinning sound. Now that I had it fixed, I still hear a whinning sound, it's just a pitch above normal. Is that common? Don't notice anything else in terms of perfomance. Nothing is grinding. Almost sounds like tires but when I take my foot off the gas, it seems to lessen somewhat. Any thoughts?

 

[imp]

Just had my real axle seal, passenger side, replaced. Was leaking fluid in addition to hearing a low pitched whinning sound. Now that I had it fixed, I still hear a whinning sound, it's just a pitch above normal. Is that common? Don't notice anything else in terms of perfomance. Nothing is grinding. Almost sounds like tires but when I take my foot off the gas, it seems to lessen somewhat. Any thoughts?

How low did the fluid level get in the center section, and how long was it driven that way? Any idea? Very low fluid level causes fluid temperature to run high, possibly thinning fluid down enough to allow scoring of gear tooth surfaces.

Just a thought. (Sorry, I try not to WORK at being like a trouble-maker!). imp

 

[Gaff It]

Not totally sure. Changed the oil not too long ago and didn't notice anything. Didn't really do any hard driving with it. I guess what you say is possible though.

 

[imp]

When axle gears make noise, the sound is a whine, almost like singing, which changes in intensity as the gears work harder under acceleration, and often quiet down when coasting with no throttle applied. This is due to the fact that damage occurs, understandably, to the higher-stressed side of the gear teeth, the "drive" side, as opposed to the "coast" side.

This is not to say that your noise problem is guaranteed to be gear-related, no way for us to tell that, given what is known. imp

 

[Gaff It]

I read many threads on here that say it is a common problem for explorers 2002 through 2005. Either the diff goes or an axle seal or pinion leaks and when fixed, the noise never really dissappears. Is more damage taking place by driving the vehicle? Ford didn't seem to think anything additional was wrong with it after they fixed the seal. I have really taken good care of this vehicle and I like to get it right, if that is possible.

 

[imp]

Please be aware, people write about their problems. Now, if Gen 3s seem to have higher share of differential noises than other Gens, it don't necessarily mean they do; there may be more Gen 3s running around out there than any others, right now, so their problems are more numerous, seemingly.

Ford Shop Manual points out some gear noise is considered "normal and acceptable". Really bad gears make noise that is just about unbearable. Are we even certain your noise problem is originating in the center section? Use of a stethoscope probe while the driveline is rotating will usually reveal the actual noise source; it will be loudest at it's point of origin, be that wheel hubs or differential center section.

Or, you could yank the center section out and replace it with a known quiet one....then, if the noise is still present.......LOL (lots of luck). IMO, the steth. is a better choice, if you can find someone willing to do it, if you cannot yourself. imp

 

[Gaff It]

Please be aware, people write about their problems. Now, if Gen 3s seem to have higher share of differential noises than other Gens, it don't necessarily mean they do; there may be more Gen 3s running around out there than any others, right now, so their problems are more numerous, seemingly.

Ford Shop Manual points out some gear noise is considered "normal and acceptable". Really bad gears make noise that is just about unbearable. Are we even certain your noise problem is originating in the center section? Use of a stethoscope probe while the driveline is rotating will usually reveal the actual noise source; it will be loudest at it's point of origin, be that wheel hubs or differential center section.

Or, you could yank the center section out and replace it with a known quiet one....then, if the noise is still present.......LOL (lots of luck). IMO, the steth. is a better choice, if you can find someone willing to do it, if you cannot yourself. imp

Taking the vehicle back to Ford tomorrow. Drove it today on the highway and after a while the noise became louder. Now I can hear it even when I am driving locally. It is more of a whining, like a bearing, and it seems to be centrally located in the rear of the vehicle.

 

[Gaff It]

It's the differential. Cost to replace $1700. Waiting time just to get the part, 2-3 weeks. Not good all the way around.

 

[imp]

It's the differential. Cost to replace $1700. Waiting time just to get the part, 2-3 weeks. Not good all the way around.

Outrageous price, unless the quote includes a brand-new unit. If you go that route, I would insist on seeing the unsealed shipping box it comes in, with the Ford part number on the label. Seems I heard they figger about 7 hours labor to R&R.

Consider a used unit from a bone-yard, easy enough to check out condition yourself before you buy it, then all you need is someone competent enough to install it. imp

Keep in mind, repair operations buy at discount, charge at retail, or higher if they can get away with it; it's a fact of over-the-barrel life for most consumers.

 

[Gaff It]

Outrageous price, unless the quote includes a brand-new unit. If you go that route, I would insist on seeing the unsealed shipping box it comes in, with the Ford part number on the label. Seems I heard they figger about 7 hours labor to R&R.

Consider a used unit from a bone-yard, easy enough to check out condition yourself before you buy it, then all you need is someone competent enough to install it. imp

Keep in mind, repair operations buy at discount, charge at retail, or higher if they can get away with it; it's a fact of over-the-barrel life for most consumers.

Yes, it is for a new unit. Having said that, I do not intend to go that route. If the truck had fewer miles on it, I may consider doing something like that. I plan to make inquiries elsewhere, at least while the truck is still running anyway.

 

[MrQ]

The whole diff? Or just to have the gears redone? What specifically is wrong with it? To get the gears redone which should include new bearings as well shouldn't be $1700. Definitely look at outside sources before swallowing Ford's expensive bull crap.


I just hate going to stealerships and detest having anybody else working on my truck, but since I have had a decent run of not screwing up repairs and rebuilds, I guess I can afford to be a little ****y. *knock on wood* :

 

[matt0248]

Ford does not do "new" differentials anymore. They used to, but stopped. It is probably a rebuilt unit. I had my 3.73 LSD diff rebuilt and it was about $2000 from a reputable shop that specializes in drivtrains. Everything was replaced except the case.

 

[Gaff It]

Ford does not do "new" differentials anymore. They used to, but stopped. It is probably a rebuilt unit. I had my 3.73 LSD diff rebuilt and it was about $2000 from a reputable shop that specializes in drivtrains. Everything was replaced except the case.

New is what he quoted me. He said you don't want a rebuilt unit. New is the better way to go. I guess I'll have to confirm again. Either way, I am going to talk to others outside the dealership. I was thinking more in the $1200 range. Guess I am out of touch with reality.

 

[matt0248]

The shop I worked at used to buy new ones from Ford. They were really cheap compared to rebuilding them. This was back in 2004 or 2005. The next time we checked on them the dealer said they don't sell the assembly anymore. I even sent a question to FordParts . com and they said the same thing.

 

[imp]

.... just hate going to stealerships and detest having anybody else working on my truck, but since I have had a decent run of not screwing up repairs and rebuilds, I guess I can afford to be a little ****y. *knock on wood* :

Just curious, have you set up ring & pinion gearsets yourself? I learned the technique back on Ford 9" units, back then certain commercial units, van, I think, came with 4.56s from factory, brand-new gearsets from Ford were under $50.00!

Today, many companies are selling copies of Ford 9", some have pressed center section housings, some even have custom CNC machined, big huge gussets, very strong. The "G-M boys" like 'em for Firebirds & such. imp

 

[MrQ]

Nope. But if that is the only avenue I have (or take it to a mechanic) then I will tear into it myself and learn along the way.

 

[my pos mounty]

It's the differential. Cost to replace $1700. Waiting time just to get the part, 2-3 weeks. Not good all the way around.

Send ericautopart (a forum member and approved vendor) a PM by clicking HERE. He has rebuilt units ready to hang under the truck for a hell of alot cheaper than 1700.
His company even sells their units to Ford dealerships, who in turn install them as new..and probably charge 1700 for.

 

[imp]

Still don't match the "shady dealings" of the U.S. Government! :thumbdwn:
imp

 

[Gaff It]

Send ericautopart (a forum member and approved vendor) a PM by clicking HERE. He has rebuilt units ready to hang under the truck for a hell of alot cheaper than 1700.
His company even sells their units to Ford dealerships, who in turn install them as new..and probably charge 1700 for.

Thanks. I am waiting on a quote to replace or to repair from a guy who does lots of these. I also sent a pm to ericaautopart.

 

[xlt03]

I checked with my FORD dealership in CA and they said no more new differentials. Only rebuilts. I sent my vehicle to differential shop and they rebuilt it for $1600.00 New ring and pinion , new bearings and seals. Mines was a 3.73 LS.