Worn differential cross shaft ?

[Exp-Wi.]

Hi guys, I recently acquired a set of Ford service manuals. I was looking through it, trying to find a cure for my front end clunk, and came across this. In the diagnosis and testing section of the Driveline chapter it states: If the condition is a clunk on acceleration or deceleration, a possible source is; worn differential cross-shaft in case. And action to be taken; replace the cross-shaft. I was wondering if anyone had anybody has tried this. It really doesn't show a picture in any of the diagrams of the cross-shaft. What exactly is a cross-shaft, and how difficult would it be to replace. I have searched and found very little info.
Thanks.

 

[RobertF]

Anyone know anything about this? My X is showing signs of this....

 

[JDraper]

Replacing a cross shaft would be pretty easy, although I've never heard of one wearing out.....

What you would have to do is remove the rear diffy cover and drain the oil. Take the retaining bolt out of the cross shaft and pull the cross shaft out. At this point, I would also look at the cluster gears to make sure the hole in them wasn't worn.

To put it back together, just make sure the cluster gears are lined up with the holes, put the cross shaft bolt back in and put the retaining bolt back in. Make sure you put threadlocker on the retaining bolt. Put the rear cover up and refill the rear diffy. Job done. Here is a pix showing the spider gears and the cross shaft.

 

[AlaskanJack]

Jdraper got anything on the front diff since that's what he was talking about?

 

[JDraper]

The guts of a front and rear differential are just about the same. Taking a front diffy out is a lot harder though. Not sure why they would say to look for a worn front cross shaft on a '93 since the diffy is disconnected in 2wd. (I'm assuming that he's talking about a clunk while driving on the road.)


The more likely source for the clunk is worn radius arm bushings. It's common in the gen I Explorers.

 

[Exp-Wi.]

still clunking

Wow, I forgot about this post. I'm still living with my front end clunk, but with 33" Dueller MTs I hardly even hear it anymore. I tried new RA bushings, tightening up coil springs so far the loud tires has worked the best. I am getting ready to start a SAS if that doesnt do it, I give up.

 

[AlaskanJack]

JDraper can you check out this post on my front diff and tell me your thoughts

http://www.explorerforum.com/forums/showthread.php?s=&threadid=83681

 

[JDraper]

Originally posted by AlaskanJack
JDraper can you check out this post on my front diff and tell me your thoughts

http://www.explorerforum.com/forums/showthread.php?s=&threadid=83681

I think you're diffy is operating normally. The funky rotation you described is probably due to the way the gears are worn and the resistance between the cluster gears and the cross shaft. I wouldn't worry about it.