2011 Ranger XLT Rear Diff Play

[maplebaconjulio]

Hello everyone, I'm posting today asking for some help diagnoising an issue and maybe just general advice on what my next moves should be considering things like cost, time, my level of proficiency, etc.

Vehicle: 2011 Ford Ranger XLT 4.0L 4x4 3.73 axle ratio 8.8" Axle w rear Disc Brakes
The issue: lot's of play in the rear differential and a clanking noise while driving

For starts, the truck doesn't have the manufacturer sticker in the driver door jam like it should so hopefully everything is identified correctly. Instead it has a sticker about tire pressure levels so there are no axle codes. There also isn't an axle tag on the rear diff.

I bought this truck in November 2022 and have always had lots of play in the drivetrain I noticed. When put in drive, there's a noticeable delay before I get that positive engagement. There's also tons of back and forth movement when just pushing the truck by hand when in park compared to other vehicles I've owned. I'm a lazy bad car owner though I'll admit so I've never investigated it further but I assumed wear in the rear diff. Recently, I started noticing a clanking noise that I assume is from the rear diff. I'm a single guy working full time though living in MO away from my home state of FL with not many friends so it's hard to get a good hand to help me diagnose noise things so I've kind of just put it off like usual. Well I finally got to looking into it because it got worse and the first thing I noticed was the pinion seal is leaking bad. I had just looked under the truck a couple of months ago maybe and didn't notice gear oil on the rear diff cover like that so I'm assuming that's more recent. So I popped off the rear diff cover fully expecting to see broken teeth on some of the gears in there but I didn't. I also didn't see any excessive metal bits or shaving in the dirty gear oil or on the filler plug when I filled it back up. I took a video of me pushing on the driver rear tire with the diff open to see the teeth engagement of the gears hoping I could positively identify where the play is coming from but I'm not 100% certain. It seems to be from the spider gears. But I'm not proficient in these things and am unsure. Also, even if it is, I don't know if that would be a sympton of another problem such as bad bearings somewhere else. Idk. I'm ignorant in this so that's why I'm reaching out. As far as my level of mechanical proficiency, I've swapped an entire axle before on a 96' Jimmy, swapped a bent axle later on on that same Jimmy, replaced rear axle shaft bearings on a 97' Blazer, and things of that nature. Nothing involving super precise measurements though. Basically just swapping parts one for one. But I do have some mechanical experience and tools to do some axle work. The rear pinion seal is very cheap and the spider gear set is relatively cheap for me. I know if I take it to a shop, not only will I be out of a truck for a while, it's probably gonna be like 5x the cost of just me buying the parts and doing it myself. But if it's something more concerning or more involved based on y'alls opinions, then I will happily take it to a shop and pay for the service. It's not the best video because of the headlamp plus phone lighting but take a look and tell me what you think. The videos are too large to upload directly so I've posted links. Thanks for your time.

This video shows the clanking and teeth moving

New video · Friday, Aug 7 🎬

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Doesn't show much, just looking around for broken/worn gears

New video · Friday, Aug 7 🎬

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[pjtoledo]

most important, does the pinion have any play? up/down/sideways
no play points to a bad seal, play means bearings.

rear axles can have lots of play.
the delayed engagement is in the transmission not the axle.

FYI, 2010 & 2011 rangers have unique rear axles. very similar to 2009 & older but not a direct swap due to brake lines, the ABS tone rings and lack of the diff sensor.
the housing ends are way different to accommodate disk brakes.

 

[maplebaconjulio]

most important, does the pinion have any play? up/down/sideways
no play points to a bad seal, play means bearings.

rear axles can have lots of play.
the delayed engagement is in the transmission not the axle.

FYI, 2010 & 2011 rangers have unique rear axles. very similar to 2009 & older but not a direct swap due to brake lines, the ABS tone rings and lack of the diff sensor.
the housing ends are way different to accommodate disk brakes.

Thanks for your response. I didn't specifically do any kind of testing to the pinion directly so I'm not sure how much play may be from the pinion itself or bearings of connected systems. I can tell you that there is a lot of movement/rotation in the rear wheels before any visible movement in the drive axle. Like quite a bit. I didn't measure these specifically but there might be like 1/8th of a rotation in the drive axle for all of the movement inside of the rear diff you see in the video. I didn't measure these but the vehicle moves maybe an entire foot back and forth for about 1/8th rotation in the drive axle during that movemnt. So it seems all the play is coming from within the rear diff carrier and axles. I can test further, just let me know what to check. I can put the entire rear on jack stands and do some more testing.

 

[SenorNoob]

I'm NOT a gears/diff guy at all...

Video with camera movement makes it hard to see much. Almost looks like the spider/side gears are moving in/out of contact with each other.

If I put my rear axle in the air with the driveshaft unhooked, I can roll the tire about 1/8 turn before the pinion starts to move. Is that good?

My next step here would probably be to try to wiggle everything inside the diff cover and see what happens. Then remove the driveshaft from the diff and wiggle the pinion flange. I'd have the seal ready to go when I did that.

Fair warning that I changed the flange on my original 7.5 rear to get the single piece driveshaft to bolt in and wasn't careful enough with the pinion nut. When I pulled the whole thing out a year or 2 later to swap to the 8.8 I pulled the cover and the oil didn't even run out it had so much metal shavings in it...

 

[maplebaconjulio]

I had to close it back up because it is my only vehicle and I did need it for a couple of days in town over this weekend. I definitely didn't do enough testing and posted this prematurely so my apologies for that. I have the option to park my work bucket truck at home so I'm gonna do that starting Monday morning and I will get this rear end in the air and leave her open for me to do some more thorough testing. I'll drop the drive axle for sure and check the pinion for play as well as just moving/manipulating individual gears inside the diff to see what happens. I'll post back here after that.

 

[SenorNoob]

Something to keep in mind. It'll probably be cheaper and faster to swap the whole axle assembly from a junkyard.

Edit: Closest one on car-part.com is a pretty good drive away.


2011 Rear Axle Assembly Ford Ranger NON-LOCKING 101,862 Miles $500
Robertson's Used Auto Parts USA-IL(Mapleton) 1-309-697-5112

 

[sgtsandman]

While there is too much play in the spider gears to me, I think there is more to it than just that. Your pinion bearings could be sloppy as well. As far as the delay, then clunk, like another said, that would be the transmission relaying power back to the axle. There could be a number off things causing the delay in pressure building up in the transmission before it sends power back.

Swapping the axle may be the easiest and cheapest thing to do. Just make sure the axle is from a 2010 or 2011 Ranger AND that it has the same gear ratio as your front axle. If you still have the metal tag on the rear axle, that will tell you what gear ratio it is since the door jam sticker is missing. Worse comes to worse, you can have the VIN number ran to look up the specifications for the truck. More than likely, it is a 3.73:1 open differential axle, since those are the most common.

 

[maplebaconjulio]

I hear y'all. The delay from engaging drive to clunk isn't necessarily a direct correlation to the play I have in my rear diff that allows me to move the truck back and forth so much even with it in park. I guess those were more assumptions I was making. Also, I wish I had some junk yards with the inventory I need to pull from but it's a rarity with this year Ranger if I want to keep my rear disc brakes. It was such a luxury with my 96' GMC Jimmy in Orlando and U Pull and Pay. I mean, I had like 20+ interchangeable vehicles at all times to pull from. It was so much fun. Always a good day. Fortunately, I can start taking my work truck home so I have time on my side. I'm in agreeance though that I'm thinking the play is probably going to be from the pinion itself and not the spider gears considering I didn't see any wear on the spider gears or metal shavings or burrs in the gear fluid. I'll know very soon. I go back to work tonight. Gonna uber to the office tonight and then I'll drive the work truck home in the morning. Then I can pull the rear diff cover again and jack up the rear end and start investigating more.

 

[sgtsandman]

I hear y'all. The delay from engaging drive to clunk isn't necessarily a direct correlation to the play I have in my rear diff that allows me to move the truck back and forth so much even with it in park. I guess those were more assumptions I was making. Also, I wish I had some junk yards with the inventory I need to pull from but it's a rarity with this year Ranger if I want to keep my rear disc brakes. It was such a luxury with my 96' GMC Jimmy in Orlando and U Pull and Pay. I mean, I had like 20+ interchangeable vehicles at all times to pull from. It was so much fun. Always a good day. Fortunately, I can start taking my work truck home so I have time on my side. I'm in agreeance though that I'm thinking the play is probably going to be from the pinion itself and not the spider gears considering I didn't see any wear on the spider gears or metal shavings or burrs in the gear fluid. I'll know very soon. I go back to work tonight. Gonna uber to the office tonight and then I'll drive the work truck home in the morning. Then I can pull the rear diff cover again and jack up the rear end and start investigating more.

The 2010 and 2011 Rangers were such a short run and are different enough from the other years, that is can be a bit of a challenge to repair for sure. FYI, if you ever need new front sway bar bushings, look at 1997-2001 Ford Explorers with a 34 mm bar. The ones listed for Rangers are way to small and won't. fit. As time goes on, you'll figure out how much of the 2010 & 2011 Rangers are a Frankenstein's Monster of a vehicle. They took parts from other vehicles and modified others, like the rear axle, to meet current regulations. So, some of it is going to be an "adventure".