Front differential chuckle on an 04 explorer.

[sattech2000]

Morning all! Helping a friend (and boss so this means brownie points) with his wife’s 04 explorer 4wd v6 flex. Has a faint chuckle that seems to be getting worse from the front. Popped the front diff cover and noticed, what looks like, an excessive amount of play with the spider gears/cross shaft. Ring and pinion look good and I don’t see any play in any of the bearings. Looks like it might be easiest to drop the whole front axle on this.

My questions are:
1) Just wondering if there are any tips I need to know about? I’ve been researching for a day now so I’m somewhat up to speed. Just want to do things right.
2) Just want to verify this is the dana super 30 axle? I have a service manual on the way. The door sticker only has two digits for the rear axle. Haven't been able to identify this axle for certain.
2) Can I just replace the spider gear assembly or should the complete differential unit be replaced?
3) Any known problem areas on these that I should pay close attention to?
4) A good source for differential parts or information related specifically to this axle? (Rebuilds, pictures, etc…)

Thank you for any help or information on this.
Randy

 

[AllanD]

a "Chuckle" if you are using the term properly is usually a result of a loose pinion bearing.

Your axle should be a Dana35-IFS

the easiest way to deal wiht it would be to swap in another complete diff unit.
(a "Yard unit")

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