Replacing front differential

NUMBSKULLXP

MEMBER
1997 FORD EXPLORER
5.0L
V8
AUTOMATIC
150,000 MILES

I have a humming noise as I decelerate and a clunking while turning sharply. I was told something inside the front differential was broken and it had to be replaced. I called a few transmission shops they had no clue about it. Is the front differential replaceable by myself? If so how would I got about doing that? Also, this is an all wheel drive vehicle.

1 Reply

ASEMASTER6371

MECHANIC
52,797 POSTS

Good afternoon.

Yes, it is replaceable by itself. It is a big job and you need a lift to perform this operation. Below is the procedure and a picture attached of the differential.

Roy

Removal:

1. Raise the vehicle on a hoist.

2. Remove the front wheel and tire assemblies.

3. Warning: Remove or tape the brake pads, to prevent them from falling out of the caliper guides.

Caution: Do not allow the calipers to hang by the hoses.

Note: Install a wheel nut to secure each brake disc in place.

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Remove the bolts and position both calipers aside.

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4. Remove the cotter pins and nuts from both outer tie-rods.

5. Note: Do not damage the tie-rod dust boots when installing the special tool. Apply a small amount of grease to the tie-rod stud.

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Using the special tool, separate the tie-rod ends from the knuckles.

6. Unclip the left and right wheel anti-lock sensor wiring harnesses from the locators on the vehicle chassis, located above the stabilizer bar brackets.

7. Warning: Do not allow the wheel knuckle to hang freely. It is possible to overextend and internally separate the inner CV joint. Separate both axle halfshafts from the front axle.

Caution: Take necessary precautions to protect the machined sealing surfaces on each axle.

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Remove both pinch bolts and disconnect the upper ball joints.
- Pull the RH axle halfshaft, with the wheel knuckle, away from the axle until the axle halfshaft is out of the axle.
- Pull the LH axle halfshaft, with the wheel knuckle, away from the axle. The LH axle cannot be removed from the axle at this time.

8. Raise the vehicle.

9. Remove the lower engine splash shield, if equipped.

10. Warning: Tape the U-joint bearing caps to prevent them from falling off the U-joint.

Warning: Index-mark the front axle pinion flange to the front driveshaft.

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Remove and discard the bolts and straps. Secure the driveshaft out of the way.

11. Note: Use the Axle Service Plugs Set T95T4850-A to plug the axle openings.

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Secure the axle housing to a suitable lift.

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12. Remove and discard the bolts.

13. Lower the axle 25 mm (1 inch) and move to the right 19 mm (0.75 inch), guiding the LH axle halfshaft out of the axle.

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14. Disconnect the vent hose from the front axle housing.

15. Lower the axle from the vehicle.

Installation

1. Caution: Install a new retainer circlip on the left inboard CV joint housing. If reinstalling the original axle housing, install a new retainer circlip on the right side.

Caution: Make sure the halfshaft circlips fully seat.

To install, reverse the removal procedure.

- Fill the front axle with the correct type and quantity of lubricant.
- Install new driveshaft bolts and straps.
- Install new axle mounting bolts.

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