Hi all,

My truck appeared to lose all gears and would grind when being put back into park. This happened naturally 2 hours into starting a vacation trip with the trailer.

Everyone even the folks at the Ford dealership in a small town kept saying transfer case. Ford even charged me $120 for that diagnosis. So naturally it took 5 days to finally get the truck and trailer back to my house via AAA towing. Now I can check the transfer case by putting it in gear and see if the drive line spins and they will tell that tale.

The tow company had an issue along the way and delivered it 17 hours later even though it was a 1 hour, 67 mile trip. They removed the drive line because they towed it with the 5th wheel attached to my truck. They started seeing smoke halfway down the highway. Turned out the was a left rear seal that started leaking and the bearing burned up. What they noticed was the the pinion where the drive line was mounted to the differential spins freely by hand with the wheels on the ground.

I know it shouldn't be doing that and I know that is a big problem. I was wondering if I remove the axle shafts to do both bearing and seals and probably a hub replacement on the drivers side, can I rebuild the diff gears with the axle still under the truck? If not I think it may be better to just swap in a used/rebuilt rear end and call it a day.

Your insight is greatly appreciated as I have not traveled down this road yet.

 

What you're asking can be (and often is) done with the axle housing in the truck. However, the fact that you're asking makes me think you don't have the tools or know how to do it. I'm not trying to belittle you either. I do most of my own car/truck work but installing a differential is something I hire done. The job requires a few tools to properly install and align all the components. Plus, I'd want to see it done to make sure I understood the process before attempting myself.

 

If your gears are toast and need replaced, take it to a shop that specializes in this realm or the dealer. As '65Ford said^^^^ it takes special tools and tedious work to get it right. And if it isn't done right, that's alot of money to **** away just to have it done right the 2nd go round.

 

Thanks for the response and no I do not feel as though you are belittling me. The differential is the only thing that I have not jumped into simply because ,in all of my years I have never had the problem come up. I just wonder why the Pinion that the drive line attaches to is spinning. I have read somethings that it is held in position by a nut and that can come loose. When I lost the ability to have gears I was starting out at a crossroad and halfway through the intersection it was like someone cut a rubber band and it was a sudden loss. Luckily I had enough momentum with the trailer to roll me to the other side and off of the read.

I already have to do a new hub, bearing, races and seals on the drivers side, so if I am going to be pulling axle shafts to do the races, bearing and seals on passenger side I may as well jump into the differential. I just needed a little guidance as to what I need to look out for and if the pinion spinning is not necessarily a terrible thing and how to diagnose that properly. Can I pull that from the side it is mounted on and can I access the nut or retainer without pulling the ring and planetary gears.

I am mechanical enough and have plenty of tools and the press I need. I understand there is a specialty tool to release the rear hub, (Naturally), so I will have to buy that one. Otherwise I have everything I need, except a little insight and guidance from the folks that know and have unfortunately been in this spot before.

Thanks in advance.

 

Assuming you have an open differential (I.e. Non-locking) then you may only have a broken axle shaft. Probably clean that up and replace yourself. Anything else would likely be time for a new ring/pinion and differential.

 

You may also have blown the spyder gears, they are easy to change on an open diff., that could also be your "no gear" problem. Differentials are easy to rebuild, if you understand them and it does take a few special tools, not necesarily the ones reccomended, but with the right measuring tools and enough understanding of what you are trying to do it CAN be done, but it is not a job to take on if you don't understand what you are trying to setup. Most people are probably ahead of the game by either taking it to a driveline shop or just swapping in another rear axle assembly.

 

Sounds like something let go in your rear axle. I doubt it was a broken axle shaft. More than likely something in the carrier or you lost the teeth off the gears. Pull the diff cover and take a good look inside. You will probably have metal chunks fall out with the oil.

At this point, my recommendation is a full rebuild. New gears, carrier and all the seals and bearings/races. There will be bits and pieces of whatever let go all thru the axle components and you will never find them all. So best just to replace them.

Oreiley's Auto will loan you tools to r/r the bearing races and seals.

I've rebuilt several GM axles in my garage that have lasted for years. I doubt the ford axle is much different. Biggest thing is to get the gear mesh patteren right. This is done by the pinion depth as to where the gears ride top to bottom on the gars and the back lash as to where they ride on the teeth of the ring gear, inside or out side.

A few helpful hints for you. When you press off the pinion gear, try not to destroy it. You want to take that bearing, if it's still in good shape, and sand the inner race just enough so it will slide on and off the new pinion gear. You will use that to set up your pinion depth. Once you have the right amount of shims and everything is checking out correct, then you will press on the new bearing with the shim stack. A good place to start is with the shim stack you take off of the old pinion.

A good dial indicator and magnetic mount is essential in setting up the gears. There are plenty of on line instructions and videos of how to do them. Watch and read before you start. Ask questions of things you do not understand.

I have rebuilt my axles both in the garage, removed from the vehicle, and under the vehicle still attached. In the garage is a lot easier, but under the truck can be done.

Good luck.

 

Get a used axle throw it in and be done. IMHO

 

The easy way to test this would be to start the truck and put it gear let off the brake and if the drive shaft turns its the rear end if it doesn't its the transfercase or something in the transmission. I'm betting the rear end.