I've been pretty vocal about the continued issues I've had with the rear differentials in these. My first rear end went at 33k miles, replaced under warranty. 6 weeks ago the 2nd rear end went at 69k miles(only lasted 36k), which Ford was willing to help with if I waited until the parts were off national backorder. I found a rear end assembly in Hermann Mo, however my dealer quoted me that shipping would be $675 almost the price of the rear end itself! I took my Explorer back from the dealer(who was going to charge almost $2000 in labor alone for this job), ordered the rear end from Missouri (UPS ground was $120 and got here in 2 days), 2 new halfshafts, and 2 axle nuts. I then proceed to download and print all the pertinent service manual tidbits off another explorer site.
All told this wasn't that bad of a job. The hardest/slowest part was the driveshaft. I had to make a tool that mimics the ford specified puller tool, and then take almost every bottom cover off the car. Having done this once, I would say to do it again would be a maybe 4hr job. Both wheel knuckles come off, halfshafts pry out, remove driveshaft, pull the 4 bolts(or 3 for some of you), and reverse.
Now to the failure. The symptom was an extremely leaky driveside halfshaft seal.. The real cause was a catastrophic bearing failure. I was told be a local sheriff that his department has had failures, with a few causing complete seizure and I can believe it.
All told this wasn't that bad of a job. The hardest/slowest part was the driveshaft. I had to make a tool that mimics the ford specified puller tool, and then take almost every bottom cover off the car. Having done this once, I would say to do it again would be a maybe 4hr job. Both wheel knuckles come off, halfshafts pry out, remove driveshaft, pull the 4 bolts(or 3 for some of you), and reverse.
Now to the failure. The symptom was an extremely leaky driveside halfshaft seal.. The real cause was a catastrophic bearing failure. I was told be a local sheriff that his department has had failures, with a few causing complete seizure and I can believe it.
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