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I had my PSD '04 regeared about 950 miles ago. I have plans to change the gear oil in the rear after break in of 1000 miles. The guy I had do the job suggested I also change the front diff. gear oil @ the same time I do the rear. If I am not mistaken, unless the front is engaged the front gears do not turn right??????? I have not engaged the front end since I had it regeared. I have never owned a solid front axle vehicle, but common sense tells me that only the "freed" hubs are spinning right, not the gears/shafts????? Can someone clarify this for me please?
You can Lock the hubs but do not engage the transfer case. The wheels will spin the drive axels, the front diff, and the drive shaft up to the transfer case. This will not wear in the ring and pinion the same as using the front differential under power. In fact the were pattern will be from the ring turning the pinion. Unless you fully engage the tranfer case you will not be putting power to the pinion to wear the face of the teeth to the ring gear.
You can look at it another way also.... I put 47,000 miles on my 4X4 2001 F250 but less than 1000 was ever with 4x4 engaged. I don't think I really care about the "break in" of the front diff for what I use it for. Now if I was planning on 'wheelin' it all the time I would have to rethink this attitude.
When I had my gear change done, I asked them about the break-in period on the front axle, because I thought to myself, it may be a few years before I put 1000 miles or more on the front axle... They said don't worry about it, number one, you don't put that many miles on it, number 2, those miles are at low speed. I don't usually drive faster than about 40mph in 4wd, so yeah, what they said makes sense... Drive and be happy.