Hello all,
So this is a new-to-me truck. 139k, in excellent shape.
I like to go through all the maintenance when i get a truck without service records(99% of all used vehicles i've bought haha)
So i know both differentials can and are driven to end of life. I don't really agree with that even though i don't tow a lot and this truck will only be driven 4k miles a year or so.

To my question: After changing rear diff fluid and, it being an expy with IRS, had the drain/fill plugs. Ok cool. On to the front diff.

Waaiiiiiiiiiit a minute here! There's no drain! It looks like the rear of my old 99 eddie bauer. So i tried a couple hoses and could not snake them down to suck the old fluid out. They just jam into something a half inch in. Is this something where i just have to pull front cover off or do i need a REALLY skinny hose to get down in there and just pull out 60cc at a time with a big syringe?
I see to remove the front cover i need to pull the drip tray thingamajig under the oil filter. I did that when i changed the oil and it was a bit of a bitch to be honest.
I'm assuming the gray silicone to make the new gasket? Like the stuff you use when putting on a gasket-less oil pan. 24 hour dry time, is that sufficient before refilling the front diff?
Thank you guys. Much appreciated.

Also worth noting: The Haynes manual is absolute garbage for the 04 expy. It's like the treat it as though it's the 04 f-150 and said "screw it, close enough". Just an observation.


***Couldn't wait. Used a small hose and pumped old fluid out. My hands are sore as hell after plunging the thing 200 times or more(felt like it anyway) but fluid wasn't that bad that came out. Judging from what came out i got almost every last drop out. Refilled, tested and my ocd can be put to bed haha

 

Consider yourself lucky, most differentials do not have a drain plug. In such a case the cover has to be removed and then a gasket made with RTV. Tip: before draining always make sure the fill plug can be removed. There's nothing more frustrating than to reassembly everything only to find you can't fill it up with fluid.

 

Absolutely. I pulled the fill plug before i even touched the drain(on the rear).
I was just surprised the FRONT diff either has to be suctioned out or the cover pulled.
I popped the fill plug on the front and it didn't have heavy nasty deposits on it. A little came running out and judging from the rear diff, this fluid was in MUCH better shape.
It'll wait until my next oil change. I'll pop the cover and take care of it then.
Decided against the suction method, it'd take forever! haha

Thanks alloro, have a good one

 

Probably didn't look that bad because according to the manual the front differential is a lifetime fluid that does not need to be changed unless there is water damage from submerging the diff. At least that is what my manual said last time I looked. I

 

Check again because I think you have it backwards. The front is standard fluid and needs to be changed. The rear is synthetic and is good for the life of the vehicle.

 

Yes, you are correct. I didn't feel the need to differ w the guy though. We all have the maintenance book so its no mystery. He was mistaken no big deal.
Also, while I'm sure the rear would go 300k normal duty use, I'd ask anyone w 100k on their rear differential to check the fluid and mainly the drain plug. You'll freak out haha. There can be a good amount of heavy sludge stuck on the drain bolt and the fluid will certainly have medal in it. It's a peace of mind thing. Plus, changing it can't hurt and can only help the diff run cooler. Cooler/smoother is better for everything.
Have a great day fellas

 

Huh. The 8.8 front diff my on 2000 EB has a drain plug.

No surprise the front fluid looked good. The front diff doesn't see near the work the rear does.

 

Unless you are willing to give him your diff, it isn't going to help him. '03 and '04 definately didn't have them, I changed fluids in both. I haven't looked at my '10 or '12 yet, I'm not in range of having to do anything.

 

The 99 i had before? I am almost positive it DID have a front drain. The rear did NOT.
The 2004 i have now is the exact opposite. I have a feeling ALL 2004s(and probably other years with the independent rear suspension) are exactly the same.

Just took her for a 650 mile trip and now i know why i had to buy another old expy. Damn these things are comfy and luggage was a breeze with the fold down seats.
That's another story. Both differentials have new fluid in them and all is well, but yes, the gen 1 and gen 2 have differences in the front/rear diff. I still can't believe they ditched the truck axle for an IRS in the 03 and up...............that's just crazy in my opiinion, but, i suppose they had their reasons.

 

Bringing this one back from the dead... My weekend project is to change front and rear diff fluid in my 04 E.B. Expy... How many quarts do I need for each? So far my list is (?) X Royal Purple 75W-140 oil, Ford Friction Modifier (unless there is a newer better option) and RTV for the front ... am I missing anything else? Also, I saw that on the ones you have to remove the pan, some people spray brake cleaner to 'clean' the inside a bit...Can I spray a bit into the drain/fill holes in the rear? I guess I'd like to clean out excess dirt, but I'm not sure how it would drain since I cant get in there and wipe excess out.