i have a 1999 ford explorer V-8 AWD XLT that didnt have the front differential when i bought it. it is a D4 axle code on the drivers door. can i just put any D4 axle coded explorer in it, and what years are interchangeable? i have found a couple 1995ish explorers that are D4 coded, but am afraid they are not gonna bolt up. is there any company that makes a solid front axle conversion kit (lockout hubs would rock, to do away with the fulltime AWD) for these AWD explorers?

 

'95-ish had a vacuum-operated axle disconnect built into the front differential, to allow gears and axles to spin without being connected mechanically through to the front driveshaft, this being used with a system allowing 2WD, 4WD HIGH, and 4WD LOW choices.

'99 lacked the disconnector, which was NOT used with AWD, anyway. Putting in a solid axle would not affect AWD at all. AWD originates IN THE TRANSFER CASE, brought about by powering the front driveshaft using a viscous clutch, similar to a little torque converter, located in the transfer case. The AWD system, by it's very intent, cannot use a front-wheel disconnecting means, whether lock-out hubs, or axle-mounted disconnect; it would not be AWD if it did.

If you did go ahead and use an earlier axle, not solid, you would have to ensure the disconnecting device on the axle remained connected, to get real AWD drive. The disconnector was operated electrically, and has a solenoid/vacuum diaphragm combination to pull it off. So, it would need to be turned on whenever the ignition were on. If you left it turned off, the Ex would work as a 2WD, and would tend to creep, or be moveable, while shifted to Park position.

If this is difficult to understand, it will be a can of worms for you. No offense, it's just that vehicles have become more complex nowadays. impish

 

Doing an install like this, I would just lock the disconnect in the engaged position, and leave it at that.
Was this actually a 4x4, or has a previous owner been refitting a 2wd? The 2wd Explorers just had a giant space where the front diff would go, but had the frame mounting points for a differential. Some brackets may be needed, I haven't looked under mine too much more to see what's between the frame and diff.