Rear differential clunk

[Danger Ranger69]

Just found out I put wrong gear oil in about a year ago. Getting a clunking noise 1-2 times a day, I've ordered proper gear oil( with posi additives) is it too late to save it. Clunked once going to store 4 miles there, but quiet returning. Also gasket or permatex oil resistant sealer? A y help would be appreciated

 

[Curious Hound]

Kind of hard to tell. I would think the worst thing you might have done is wear out the friction discs for the limited slip. They should be replaceable. You really need to get it where you can crawl under and push and pull and rotate things by hand to find out if you have abnormal wear on something.

What "wrong oil" did you have in it?

 

[scotts90ranger]

The oil likely isn't your problem... if the clutches in the diff are factory they're probably worn out. My '00 Explorer made a clunk every now and then and it was the spider gears skipping a tooth... when I got the dumb thing they were full on stripped out. One of the problems with these limited slip axles is as the clutches wear it pushes the side gears further out and in extreme cases they stop engaging the spider gears... I solved my problem by welding everything into a solid unit but that is not recommended for a daily driver, me I was giggling the whole time since it's just a fun rig at this point... it really doesn't like turning on hard surfaces especially when towing my boat...

 

[Danger Ranger69]

Kind of hard to tell. I would think the worst thing you might have done is wear out the friction discs for the limited slip. They should be replaceable. You really need to get it where you can crawl under and push and pull and rotate things by hand to find out if you have abnormal wear on something.

What "wrong oil" did you have in it?

Straight 80-90wt gear oil. Was off grid camping 4 months bored, checked fluids. Down on oil. Guy had some. Filled up about 14 months ago. Probably put 2 litres in. Thanks for that. Got proper oil. Was going to crawl under and pop cover off and check, when it's not -20

 

[Danger Ranger69]

The oil likely isn't your problem... if the clutches in the diff are factory they're probably worn out. My '00 Explorer made a clunk every now and then and it was the spider gears skipping a tooth... when I got the dumb thing they were full on stripped out. One of the problems with these limited slip axles is as the clutches wear it pushes the side gears further out and in extreme cases they stop engaging the spider gears... I solved my problem by welding everything into a solid unit but that is not recommended for a daily driver, me I was giggling the whole time since it's just a fun rig at this point... it really doesn't like turning on hard surfaces especially when towing my boat...

Thanks. Just waiting for warmer weather. -20 right now

 

[scotts90ranger]

If you were around 2 quarts low no doubt your clutches are shot, I would just grab a clutch rebuild kit and be ready while you have the diff cover off, it's not super hard other than wrestling with the S spring and hopefully the cross pin bolt is intact, from there you can probably pull one tire, slide the axles in enough to get the C clips out and get the job done... Assuming you have 3.55 or 3.73 gears the s spring isn't too bad but it doesn't want to come out...

 

[Danger Ranger69]

If you were around 2 quarts low no doubt your clutches are shot, I would just grab a clutch rebuild kit and be ready while you have the diff cover off, it's not super hard other than wrestling with the S spring and hopefully the cross pin bolt is intact, from there you can probably pull one tire, slide the axles in enough to get the C clips out and get the job done... Assuming you have 3.55 or 3.73 gears the s spring isn't too bad but it doesn't want to come out...

Thanks very much. Greatly appreciated. In Canada . Phone around to see where I can get rebuild kit tomorrow. Have a Happy New Years

 

[Danger Ranger69]

Kind of hard to tell. I would think the worst thing you might have done is wear out the friction discs for the limited slip. They should be replaceable. You really need to get it where you can crawl under and push and pull and rotate things by hand to find out if you have abnormal wear on something.

What "wrong oil" did you have in it?

80-90 weight with no friction modifiers. Does have 140 k. So maybe just worn. Tuesday is only -6. Go out then take cover off then inspect.