Nope I didn't check. I've drained in and check the gears out. they seem to be ok. cleaned and painted the cover and resealed using "right stuff". I have 5.4 pnts going in and believe thats what the manual calls for. This includes the modifier. So in sense it is pre measured, so it should be ok to fill through the sensor hole?

Front shocks are just about finished.... they were toast!

 

A dark color I hope?

 

Why not just fill it through the correct plug?

 

I thought you were supposed to paint it orange...isn't that why they call it the pumpkin

 

I asked because painting the cover a light color reduces the life of the differential by trapping heat inside.

 

Where is this fuse located?

Just to update this thread as well, the oil change never made of differance. To date i have replaced, RT hub, inner and outer tierods, CV half shaft, all new brakes. Now I've got the steering box and steering shaft out. Seems to be some excessive play. Even though I think that might be the problem I'm not keeping my all eggs in one basket. To date $600 in parts and the only thing gained is the grinding is gone and I've learn some new 4 letter words..

 

In the fuse box.

Which one exactly depends on the year and/or Expy/Navi model, which you didn't post.

 

Thank you. I think is 104?

 

Ok, so the grinding noise is gone. What problem are we trying to fix next?

Mine has a front end noise too. I have traced it to the idler arm. It causes a bit of a clunk on speed bumps, or when backing up at full steering lock.

Check it by lifting one wheel up and trying to turn the wheel by hand. Idler arm is on the pass side frame connected to the center link.

I did new ball joints recently and they started squeaking. Even though they came greased, I pumped some more in there and it fixed the squeak.

What is the current symptom?

I would also keep in mind that even though you have spent $600 in parts on a ten year old truck, that is about one months payment on a new one You are still way ahead of the game.

 

I don't mind spending the money. The problem is I've had it apart 3 times and each time I go through it I can seem to find the problem.

Symptom is now when driving something is loose in the front end. Clunking,popping. Doesn't matter if your turning or just driving regular. Any speed. it has progressivly gotten worse. Thats why I took the steering apart.

I have gone through that front end completely and there is nothing else loose or has play in it.

After some searching last night i'm also finding out that theres also transfer case issues. so if this next step fails I'm going to go in that direction.

again just a bit frusterated with no finding the problem. fortunetly though we have other cars in the meantime.

 

Yes for a 2000 Expy it's fuse #104.

 

Well got the truck put back together. Still did the same thing when driving it.
I then removed fuse #104 and the problem went away. So at least now I know that its something to do with the transfer case.

Where should I start? Sensor locations or maybe a link to some sort of diagram?
thanks

 

I believe the sounds you are describing are the classic sounds of the T/case chain coming apart. It happened in my son's Mountaineer and there are several others that have posted about the same sound that turned out to be the chain. There are some pics in my gallery you can look at. The case needs to come apart for inspection and it would be a good idea to gave a chain on hand before starting, you can return it if it's not needed.

 

Thats gonna stink!... I assume in order to do this I have to remove the transfer case and split it?

But before doing that should I check speed sensors,and the motor for the t case just to eliminate those possiblities?
thanks

 

Check out mwkobe's posts in the Explorer forum, he says he can do it in the truck. That is a different vehicle but it may be possible. I don't think the speed sensors or the motor will be the answer.

https://www.ford-trucks.com/forums/9...nsfercase.html