Wounded Pony,,,need some options

[tooluser151]

03 mounty 4.6 v8 AWD front diff. went on me,trying to figure out best way to
attack, short of a swap for a few months. I don't know if there is some sort of rebuild kit in this situation or not.

a man not doing is a man not trying,,,get it done!

thanks too all that come to aid

 

[Ronin8002]

Don't know if pulling the front driveshaft is an option on an AWD until you can get it fixed, but maybe that would make it driveable.

Swapping it out with another complete unit is not too terrible, just get a replacement from any 4wd or awd explorer/mounty/aviator of the 2002-2005 range in the correct gear ratio...usually can find those at a junkyard. Depending on what the problem is, that might be a cheaper option that having it rebuilt.

03 mounty 4.6 v8 AWD front diff. went on me,trying to figure out best way to
attack, short of a swap for a few months. I don't know if there is some sort of rebuild kit in this situation or not.

a man not doing is a man not trying,,,get it done!

thanks too all that come to aid

 

[tooluser151]

I guess this is my problem

 

[tooluser151]

looks like the RTV gasket failed

 

[tooluser151]

 

[xsportx]

Looks like your pinion seal is shot to me... I just did mine about 3 weeks ago, not a bad job.

 

[tooluser151]

thanks xsportx

not to sound slow, but what did the job consist of and how much, around about estimate I'm new to this area of repair, but can get the job done w/ some step-by-step or diagram, because right now I need to get my hands dirty {- _-}




thanks again for reaching out
all aid is valued & respected

 

[tooluser151]

I really can't find alot of info on the front awd diff. as I can for a rear diff., so once its dropped do it tear-down the same as other front diffs, could not find a exploded view as to parts that could fail or become damaged to do a proper repair





any & all help, thanks

 

[Ronin8002]

It's a Dana Super 30, specific to the Ford Explorers.

Pinion Seal isn't too bad a job, looks like that's what it is.

 

[tooluser151]

Hey, Ronin8002 thanks

So knowing it's a DANA SUPER 30, is that a given on the ratio or will I have to look further for the pacific gear ratio?
Also it seem like the opinion seal, RTV gasket are done and U-joints have to be replaced and I still havn't cracked the cover to maybe find any internal damage.
If I swapped out w/ junkyard swap how would I know if I'm getting a better than I got? any tips.



thanks to (Serious Explorations) forums
this is the most support I've gotten
thanks 2 u all

 

[Ronin8002]

So knowing it's a DANA SUPER 30, is that a given on the ratio or will I have to look further for the pacific gear ratio?
Also it seem like the opinion seal, RTV gasket are done and U-joints have to be replaced and I still havn't cracked the cover to maybe find any internal damage.
If I swapped out w/ junkyard swap how would I know if I'm getting a better than I got? any tips.



thanks to (Serious Explorations) forums
this is the most support I've gotten
thanks 2 u all

I don't know about the ratio. You'll have to see what's on the tag on the long tube that sticks out on the passenger side of it. Sometimes there's one on the cover attached to one of the bolts. If all else fails, look at your door tag for your axle code and look that up...that tells you the rear end axle ratio which of course has to match the front axle too.

What makes you think its damaged internally? If its just leaks you can take the cover off with the diff installed on the truck and do a quick inspection. Also the pinion seal repair can be done with the diff in the truck.

I know alldatadiy.com has all the info on the diff with the diagrams and such. Worth the small fee to sign up in my opinion, has paid for itself for me many times over.

 

[tooluser151]

U the man Ronin8002
I'll track down the ratio now that I have direction.
Also I heard a clunk & maybe a clack right before I pulled over, not sure if it was because the
fluid bleed out or possible internal damage? So I had her tow on a flatbed home.
An as to ALLDATAdiy.com I wasn't sure that they would have pacific info relating to the differential or not, had a friend look on michell' on-demand and nothing came up, but did have limited info on TC, so I will check out alldatadiy.com,, thanks 4 those long-arms & reaching out

 

[Ronin8002]

No problem. Alldatadiy has what you need. I just looked this morning and there are steps with diagrams on tear down and re-assembly.

If you need replacement parts then you can go to www.ringpinion.com, they have gears and bearing kits/rebuild kits.

 

[tooluser151]

Good Morning forum family

Ronin8002, I did find the ratio which I believe is 3.73; thanks to your direction.
funny around 4am I came across ringpinion.com and found just the one rebuild kit, Yukon Master Overhaul kit for Dana "Super" 30 differential, '01-'05 Ford front for $256.
signing-up for the ALLDATAdiy.com!!!!

Also should I change the rear Diff. oil & TC oil at this time, and what other things should I be concerned about related to this repair if any?
Got my sleeves rolled up and ready {-- _ --}

a man trying is a man doing,,, gettin her done!!!


truly valued & respected

 

[Ronin8002]

Might as well change the oil in the rear diff and tcase while you're at it, if you have the time/$$.

 

[tooluser151]

thanks much, will do.
by the way alldata mention preload in the removal of the pinion flange, not really understanding that part; will I stabilize the flange while I remove the nut? And do I
have to reinstall with the same amount of preload or I'm I totally wrong.

 

[Ronin8002]

thanks much, will do.
by the way alldata mention preload in the removal of the pinion flange, not really understanding that part; will I stabilize the flange while I remove the nut? And do I
have to reinstall with the same amount of preload or I'm I totally wrong.

You need an inch lb torque wrench to measure pinion preload. It's how much tightness is on the crush sleeve inside the diff. Google pinion preload and also look on YouTube and you'll get a lot of info on what it means.

 

[tooluser151]

thanks, Ronin8002

 

[tooluser151]

Hey, forum family just an update

Here's where I'm at with my repair, pop the cover on the pumpkin did a visiual inspection, gears looked ok the teeth in good shape, didn't find no crudd build-up just oil hadn't changed in a while, sprayed it out with the brake-kleen and clean up the mating plate and cover; installed new RTV gasket.

Next I dropped the front drive-shaft in an attemp to replace pinion flange seal,
noticed the pinion flange had no preload, about 1/2 - 1in play without removing the nut. My concern is can I just remove the nut and not worry about measuring preload at this point, or if it should just be replced? If I can reuse can I regain preload if I tighten down the nut that 1/2 - 1inch in small doses? I did mark the flange, stem and nut for reinstall.

Mean-while I did installed new U-joint and stop there.

Checked the rear drive and found a leak; I believe is coming from the rear pinion flange seal from TC, have not got that far in the repair, but gett'in her done.



keeping it moving,
thanks guys & gals
for being out their!

 

[Ronin8002]

If preload was too loose to start with, you can tighten it up.

If preload was too tight or you don't tighten it enough when you reinstall the pinion flange, then that's not good.

At least that's how it was explained to me. Just make sure you get at least the same amount of preload when you reinstall the pinion nut and you should be OK.