03 Explorer - differential leak
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Cross-Country
Joined: May 2003
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03 Explorer - differential leak
My differential is leaking a bit. Can someone please give me an idea of how hard or easy it is to replace the seal and oil? What should it cost to have it done. I was told 3-4 hours by a garage and that seems high. Thanks.
Fleet Owner
Joined: Mar 2003
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From: Blue Hill Township
Where is it leaking from? If its the cover thats not a big deal to replace. Drain the oil, rtv the mating surface and put the cover back on and fill 'er up.
If its the pinion seal, I've heard thats an easy fix as well. Don't quote me on this as it doesnt seem right, but I've heard its around $100 to have that replaced at the stealership
If its the pinion seal, I've heard thats an easy fix as well. Don't quote me on this as it doesnt seem right, but I've heard its around $100 to have that replaced at the stealership
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Cross-Country
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Thanks for reply. Am new at this. Can you give me a little more info on the rtv, what it is and how it should be applied? Is it just a gasket adhesive that you put around the perimeter of the cover to hold the gasket in place, or some other special thing that's used? Is there a brand name that's used?
Fleet Owner
Joined: Mar 2003
Posts: 24,724
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From: Blue Hill Township
You can find RTV at any parts store. It is used to make a seal between things. I always use RTV instead of a gasket for rear differential covers. As long as you have a nice bead around the edge and around all the bolt holes it shouldn't leak on you again. Like I said, you can pick it up at pretty much any parts store.
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Cross-Country
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Thanks. Is there anything to removing and reinstalling the differential cover besides unscewing a few bolts and torquing them down? Any other things to do? What's best way to get oil back into the case, since I'll be working under the truck with not much room?
Fleet Owner
Joined: Mar 2003
Posts: 24,724
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From: Blue Hill Township
Are you sure that its coming from the cover, or is it coming from the pinion seal?
Dropping the cover is pretty easy. Take out the lower bolts first to drain out the pumpkin. You'll find a fill plug on the upper drivers side of the case. It should come out with a 3/8" extension and a ratchet. Just pour/pump fluid in until it comes to the bottom of the fill hole. IIRC its around 3 bottles of gear oil.
Dropping the cover is pretty easy. Take out the lower bolts first to drain out the pumpkin. You'll find a fill plug on the upper drivers side of the case. It should come out with a 3/8" extension and a ratchet. Just pour/pump fluid in until it comes to the bottom of the fill hole. IIRC its around 3 bottles of gear oil.
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Cross-Country
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Thank you. Not sure where exactly. Just looks like a fluid leak around the perimeter of the pumpkin (and on the garage floor).
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Fleet Owner
Joined: Mar 2003
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From: Blue Hill Township
Clean it up under there with brake cleaner and a rag. That way you can see exactly where the leak is coming from.
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OKOKOK... is this a FOUR DOOR EXPLORER or is this an EXPLORER SPORT/SPORT-TRAC.
The difference is.. independant or solid rear axle..
If it's independant (on the new design 02+ 4 door explorers) most likely the leak is the axle seals... not much different than replacing seals on a front-wheel drive car. Just remember to USE THE MUCH THICKER NEW DESIGN seals... and in the process you have to tap off the "dust shields" on the inboard ends of the axles. The new seals do not require them and if not removed they will not allow the axle to seat fully, thus causing a leak of its own (likely in maceslin's case).
If it's a solid axle design (in the sport/sport tracs) then most likely it's the pinion seal. You can remove the pinion nut and use a puller to remove it.. pop the seal out.. install the new seal.. and tighten the pinion nut just enough to start to compress the crush sleeve just a bit more, but not too much, or you risk bearing damage.
Good luck
The difference is.. independant or solid rear axle..
If it's independant (on the new design 02+ 4 door explorers) most likely the leak is the axle seals... not much different than replacing seals on a front-wheel drive car. Just remember to USE THE MUCH THICKER NEW DESIGN seals... and in the process you have to tap off the "dust shields" on the inboard ends of the axles. The new seals do not require them and if not removed they will not allow the axle to seat fully, thus causing a leak of its own (likely in maceslin's case).
If it's a solid axle design (in the sport/sport tracs) then most likely it's the pinion seal. You can remove the pinion nut and use a puller to remove it.. pop the seal out.. install the new seal.. and tighten the pinion nut just enough to start to compress the crush sleeve just a bit more, but not too much, or you risk bearing damage.
Good luck
New User
Joined: Mar 2008
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Sumdumgai,
Have you resolved the leaky differential issue? I own 2003 Explorer and I do have a leak now and I am trying to isolate it.
Did you find the problem? How much money did you end up spending? Any information would be great. THANKS.
Have you resolved the leaky differential issue? I own 2003 Explorer and I do have a leak now and I am trying to isolate it.
Did you find the problem? How much money did you end up spending? Any information would be great. THANKS.
Tuned
Joined: Nov 2003
Posts: 339
Likes: 1
Axle seals are the main culprit for leaks in the rear.My 02' Explorer leaked and had it in the dealership about three times until they got it fixed.My inlaws 02' Mercury Mountaineer did the same thing and they took it in for new axle seals.Both vehicles leaked well below 50k miles.
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