1995 4x4 351w F150 Flareside gear problems
 

I am having problems with either my transfer case or rear axle as far as i can tell when i am at stop and start to go the gears feel like their slipping or poping. The transfer case is a borg warner i believe T35 and it has a slight leak on it and i just did a 3200 mile round trip and the symptoms started during the last 800 miles of the trip. I pulled the fill plug on the transfer case and it was low on fluid so i drained the fluid and put fresh mercon tranny fluid in. I also added 80-90w gear oil to the rear axle. Everything is stock on the truck, and the tranny is an E40D with a deep pan. Any help on this matter is greatly appreciated.

Does the sounds eminate from the rear of the truck? It's probably a good idea to remove the rear diff cover and inspect the gears thoroughly, if something has worked loose and you can find it you may avoid having the rear end completely destroy itself.

Probably the rear end, there is little that can go wrong in the transfer in 2wd high. The rearend however can destroy itself it it gets to hot on a long trip like the one you just finished with low oil, I bet you were also hauling a load, I killed a 9" rearend moving cross country and it did a very simalar thing I totaly killed the pinion bearings and the pinion was sliping past the ring gear destroying each other. So pull your diff cover and take a look.

I will pull the cover off and look to see...what gear oil would i need to put in the axle? Thank you for the advice.

OK when you tale off the cover on top of taking a good look you should also pull the crosspin and inspect the pin and C-clips. This is pretty easy, you'll have to take the tires and drums off though. After removing the tires and drums and before removing the cover, grab the axle flange and try and push it in and pull it out (on both sides) it will move back and forth a bit but shouldn't be more than about 1/8th", if it does it needs work. Also a good idea to try and give the pionion yoke a good shake and make sure it doesn't move. Then after you pull the cover and inspect the ring and pinion gears real good with a good light, pull the crosspin it's pretty easy. Turn the diff until you see a small bolt on the outside that crosses the crosspin, this bolt retains the pin take it out then the pin will slide out the end. The crosspin is the inner thrust surface on a 8.8 so take a good look at where the axle rides on it. If you go this far you might as well go all the way and pull the axles and spider gears to take a look. After pulling the crosspin push both axles in this will allow you to remove the C-clip, take a good look at it for wear this is the outer thrust surface and retains the axle it's important. After all that the spiders will rotate out real easy if they haven't already fallen out, so ou can take a good look at those, and if it's a posi, the clutches.

Let us know what you find.

SAE 85/90 wt gear oil.

Thank you for the directions and I will definetly keep you posted on what I find, again thank you guys for all the information.:)

well i know its been awhile since i posted this thread...the rear axle went to pieces on the count of no gear oil and high temps from long trips, when i bought the truck i forgot to have this as an item to do and so i paid the price and had to buy an axle, luckily there was a guy parting out his f150 and got his good axle for $50...whewwww