Rear Differential Capacity...Owner's Manual Typo?

[JoshMcMadMac]

I have a 2002 Mountaineer, 4.6L, 2-wheel drive. I just changed the rear differential fluid, pursuant to a pinion seal replacement. As far as I am aware, the 8.8" IRS was the only option on this vehicle, with a choice of limited-slip or not. I checked the manual before all of this and it states a capacity of 5.5 - 5.8 pints...almost 3 quarts. This made me very confused when I could not quite manage 2 quarts into it, even with the rear jacked up. I then searched around a bit, and there are several threads here that go over this and how the capacity is just under 2 quarts. Here are two examples:
http://www.explorerforum.com/forums/showthread.php?t=289561
http://www.explorerforum.com/forums/showthread.php?t=248273

The first link even has a picture from a .pdf version of the 2004 manual showing 3.5 pints...and I do not think anything changed for the rear differential between 2002 and 2004. Is the manual incorrect, or perhaps a carry-over mistake from the previous generation?

 

[techieman33]

The capacity for a 2nd gen is around 5.5 pints and the capacity in a 3rd gen should be less since there is no fluid going into the axle tubes.

 

[JDraper]

Just fill it until it's at the bottom of the fill hole. That's the correct way to do it.

 

[JoshMcMadMac]

Just fill it until it's at the bottom of the fill hole. That's the correct way to do it.

No crap, but that does not address my question...

The capacity for a 2nd gen is around 5.5 pints and the capacity in a 3rd gen should be less since there is no fluid going into the axle tubes.

This sort of addresses my question. So I am guessing it was a carry-over mistaken in the 2002 manual?

 

[xlt03]

I had same result, just barely got 2 qts in after the drain and fill including the friction modifier for my limited slip. You didn't do anything wrong.

 

[jmedina827]

Barely 2 qts. total for my 2005 Explorer AWD.

 

[drdoom]

Just fill it until it's at the bottom of the fill hole. That's the correct way to do it.

Wrong for an '05 you fill to hole then plug then add 8 ounces through the ABS sensor port. Not sure about an' 02.

 

[Green98XLT]

Wrong for an '05 you fill to hole then plug then add 8 ounces through the ABS sensor port. Not sure about an' 02.

Drdoom- Please show me where it says to do this? EVERY rear I've ever serviced (and thats been many) you fill til it begins dripping out of the port and its full, anything more is overfilling.

 

[drdoom]

I can post it later, we have the Ford 2005 Mountaineer/Explorer shop manuals here, that is straight from the book. May have been updated since but AFAIK it's good. Like I said, other models may differ. PS front diff you fill in the usual manner. Best wishes.

 

[Green98XLT]

I can post it later, we have the Ford 2005 Mountaineer/Explorer shop manuals here, that is straight from the book. May have been updated since but AFAIK it's good. Like I said, other models may differ. PS front diff you fill in the usual manner. Best wishes.

Any clue on the 02-03 models? I just serviced both Diffs on my 02 and did them the standard way of only filling to the plug

 

[drdoom]

Green, my apologies but I really don't know about those years, hopefully other members with those models can check into it.

 

[leadfootdriver]

I have an 02' independent rear. I wanna say I only got 1.5 quarts in there.

 

[drdoom]

Thanks leadfoot, I assume that was to the fill hole with the vehicle level. What we are trying to find is someone with the Ford workshop manual for that year, to see what that says as far as the 8oz overfill. Thanks again.

 

[leadfootdriver]

Best of luck.

 

[swshawaii]

2002-05 Roll Stability Control (RSC) vehicles only? Source of instructions to add friction modifier thru the ABS port still NOT given. :scratch:

Need Clarification on REAR DIFFERENTIAL OIL CHANGE
http://www.explorerforum.com/forums/showthread.php?t=375714

Differential fluid change
http://www.explorerforum.com/forums/showthread.php?t=334975

Differential overfull?
http://www.explorerforum.com/forums/showthread.php?p=3133095

 

[1950 Ford woodie]

I have a 2002 Mountaineer, 4.6L, 2-wheel drive. I just changed the rear differential fluid, pursuant to a pinion seal replacement. As far as I am aware, the 8.8" IRS was the only option on this vehicle, with a choice of limited-slip or not. I checked the manual before all of this and it states a capacity of 5.5 - 5.8 pints...almost 3 quarts. This made me very confused when I could not quite manage 2 quarts into it, even with the rear jacked up. I then searched around a bit, and there are several threads here that go over this and how the capacity is just under 2 quarts. Here are two examples:
Differential oil question
How much diff lube do I get?? What brand to get...? Rearend whine/roar....

The first link even has a picture from a .pdf version of the 2004 manual showing 3.5 pints...and I do not think anything changed for the rear differential between 2002 and 2004. Is the manual incorrect, or perhaps a carry-over mistake from the previous generation?

Coming to the party late, but I filled the 1996 Explorer 8.8 diff in my 1950 Ford wagon to the fill hole, and it leaked out the axle tubes, even after replacing the seals. The dealer says the capacity is 5.5 pints, and it should not be filled any closer than 1/2 to 9/16 inch BELOW the fill hole. Mine has the W140 tag, and he said it needs 75W140 synthetic lube.

 

[drdoom]

Coming to the party late, but I filled the 1996 Explorer 8.8 diff in my 1950 Ford wagon to the fill hole, and it leaked out the axle tubes, even after replacing the seals. The dealer says the capacity is 5.5 pints, and it should not be filled any closer than 1/2 to 9/16 inch BELOW the fill hole. Mine has the W140 tag, and he said it needs 75W140 synthetic lube.

Maybe the axles are worn, and need repair sleeves. Also make sure you have a good vent.

 

[swshawaii]

Coming to the party late, but I filled the 1996 Explorer 8.8 diff in my 1950 Ford wagon to the fill hole, and it leaked out the axle tubes, even after replacing the seals. The dealer says the capacity is 5.5 pints, and it should not be filled any closer than 1/2 to 9/16 inch BELOW the fill hole. Mine has the W140 tag, and he said it needs 75W140 synthetic lube.

Were you using the stock fill location, or the fill plug on an aftermarket cover?

Most, if not all aftermarket cover fill holes are much higher than the stock fill location on the axle.