Hey FTE!!!

So been a vivid reader of these forums for some time and have helped me troubleshoot through many issues. However im stuck on a new one that I can't seem to gather info on.

I own a 2002 F350 XLT with a 7.3L.

So here is my story:

While driving the truck the famous rear diff cover sprung a hole and leaked out all fluid while going up and down in the mountains on pavement. Rear diff cooked I towed the vehicle home and started my search for a rear diff. I went on some ill advice that all rear diffs on super duty's are the same.

I bought a 2006 F250 with a 5.4L parts truck only.

I swapped the diff over and almost everything lined right up. The first problem i noticed is that the rear brakes were much bigger on the parts truck and the hubs seemed to be different giving the wheels a wider offset. I moved all my brakes, caliper's, hubs, backing plates, parking brake shoes over to the diff out of the parts truck and installed it all. Bolted up perfectly and didn't see much wrong until i went to torque the bearing/hub locking nut (one which requires special 4 pronged style socket not sure what its referred to as). I notice that when i reach 60 ft lb of torque the hub still has a good amount of play. If i tighten the nut more my hub will eventually touch my parking brake shoes. I reinstalled everything thinking maybe the axle would snug the hub up but the rear axle seals will not seal and just **** fluid while driving as the hub has play. I only drove the truck for short distance and is now on the hoist.

Is there some sort of spacer or something missing? Has anyone experienced this before? What are my options?

 

You should have gotten your hands on a '99 to '04 rear axle assembly. '05 and up Super Duties use a completely different front and rear suspension of different dimensions as you are finding out now.

 

So im looking for another rear axle assy 99-04?

 

That is correct.

 

Just noticed you are from Brampton!! Im up in Ottawa.

Do you know if i could move all the internals from the 06 diff into the 02 diff to rebuild my blown one?

 

If you only need the crown and pinion assembly itself, I'd say yes. But you may need to install new pinion bearings in the process. Just make sure your pinion depth, pinion bearing preload and ring gear backlash specs are correct when going back together. And you will still need to use your original brake parts, hubs and shafts. I believe those are 10.5" Sterling axle assemblies we are working on by the sounds of things.

 

Thanks!! I'll search for a rear diff assy to get the truck going then rebuild myself a spare on the side. Thanks for your help!!!

 

Will the complete axle assembly you have fit in your truck?

 

yes its in the truck... but it pisses gear oil due to the fact the hubs never tighten up and the excessive play causes it to leak.

 

Are you using the hubs from your truck or the donor truck?

 

From my truck. The one from the donor truck has different size brakes(bigger) and it seems the wheels sit a bit wider aswell. I was informed by someone that the rear axles were the same if i moved everything over which has me stuck in the current predicament... On a long weekend when i need the truck haha!!

 

I would have tried to use the COMPLETE rear axle from the donor truck. Hubs, axles, brakes & all.

 

That would have been ideal but it would have created a weird stance as the rear would have a wider offset then the front.

 

Better a weird stance than a leaky axle. You could swap the rear wheels from the donor truck and everything will line up. May look a bit funky though with mismatched wheels.

 

I have aftermarket wheels. i found a diff im going to swap. truck is on hoist not a huge project.