*** Urgent *** Front axle problem

[Nate1]

While checking everything and preping to extend my breathers for tomorrow, I found that the little L shaped valve that connects the tubing to the front diffy houseing had POPPED OFF! I am frantically trying to get it back in tomorrow, I dont know how long it has been out, but I know it needs to be in tomorrow. It is not threaded to screw it, but it does have raised metal bands. I cant seem to get quite enough leverage to get it in, and I need to do it ASAP tonight!

I NEED HELP! Any tips or tricks appreciated!

-----Nate

 

[Nate1]

Anyone, any help? BTT

 

[Nate1]

Ok, I've tried everything from cleaning the treads in the connector to greasing it and using washers to get more surface area to push with. I CANNOT get this thing to go in. It now becomes a question of: who can I take this to without having them say 'only way to do it is to drop the axle'. There has to be some tool or some way, but searching my Ford CD, I havent found anything. I am going to call my 'trusted' (sorta) shop tomorrow and see if they think they can do it, but what should I estimate as far as repairs, and what other types of shops could do this sort of thing?$$$
Agh, what a way to ruin a perfectly good weekend of 4x4ing! :fire::fire::fire::fire:
-----Nate

 

[boominXplorer]

you try twisting as your pushing it on?

 

[Nate1]

Yes, tried sticking screwdrivers in the hole and pushing with them. I have tried anything and everything. It must have been really hard to get out. Can any 2nd gen's see how theirs feel or take a picture of it. The exactly angle that it goes in and the distance it goes in may help.

 

[JDraper]

That piece is usually pressed in from the factory and will probably be a PITA to get back in. You may have to end up reaming the hole a little and epoxying the piece back in place. Here is a pix of the fitting. I took it from behind the axle facing forward.

 

[Nate1]

Arugh! I dont have the slightest idea how to ream the hole, and would epoxy stick on grease? I almost JBwelded it, but decided that wouldn't be the best idea.
I'm trying to make a service appt with ford to see if they have any tool or way to force it back in. I still have NO idea how it came out, or for that matter how long it has been out

 

[JDraper]

You're probably gonna have to drop the front axle to do it. It's not as bad as it sounds. The axle itself is only held in by 3 main bolts. You have to disconnect the front driveshaft from the diffy, unhook both upper ball joints and pull the CV joints out of the axles (Ball joints have to be unhooked to tilt the spindles far enough out for the CV joints to clear the ends of the axle). The CV joints are not bolted to the axles, they can be popped loose by carefully placing a screwdriver or prybar between the axle and the CV joint and prying it outwards. At this point fluid will flow out the axle ends, so be prepared to catch it. There are then 3 bolts that hold the whole axle in place. Two are on the driver's side and one on the passenger's side. Pull them out, and the axle will come out. I pulled the axle out of a '96 X this way in about 1 hour. If you have a Haynes manual, it has pix and the steps on how to do it. HOWEVER, in the manual, it says you have to remove the axle ends from the spindle brackets....You don't have to. There is enough room to get them out without doing that by playing with the steering wheel a little. You will find a position that will allow the CV ends to clear the axleshafts.

 

[Nate1]

I took it to ford today and they said the would do my balljoints for $450 and pop the thing back in at the same time (for free). They said they have a tool they are pretty sure they can do it with. I'm not thrilled about spending all that money, but I need to do balljoints anyways, and I dont have the tools or know-how to drop the axle.
Thanks anyways.

 

[JDraper]

Sheesh! All that typing for nothing!!!