Hey guys, new to the forum and new owner of a 1997 Aerostar 4.0 awd. Jack the car up the other day to do the front brakes and found that our the rod is bowed and the drivers axle is ****ed. I'm not sure how the axle connects to the differential, and so I figured I would ask before tinkering with it. I'm used to working on European fwd cars where the axle has 6 bolts on the diff side. The Aerostar looks like it should as well but they are all missing and it's just a plate there now from where the axle broke. Can't seem to find replacement bolts or videos specifically for aerostar axle replacements. I found one for a similar year explorer and it looks like the axle just slides in to the differential. Can anyone help me out? Thanks in advance!

 

There are 6 bolts that hold the inner end of the half-shaft to the differential. It looks like you lost all of them. There was at least one other case where this happened:

https://www.ford-trucks.com/forums/1...bolt-size.html

If the holes in the flange on the differential are not gouged out, you should be able to find replacement bolts. Clean out the threads and use a permanent thread locker.

That tie rod looks like it's experienced a severe bump, or someone adjusted the toe with a crowbar. I would look closely at it to see if there are tiny cracks on the outer radius, and replace it if it does. Of course, if it was caused by a bump, you might want to replace the rack.

 

Oh MY! you have alot to fix. I just did a new rack and tie rods, very easy and cheap through rock auto. Except I had to do it twice, the first one they sent me leaked.
Looks like you better stock up on hand cleaner.

 

That old half shaft is shot, boot worn and torn by the bolt shield.
Replace, Rockauto sells new Cardone for about the same price as the junke rebuilds. Been running new Cardones in mine for 100k + miles. Come with new bolts.
Use a tap to clean the threads out in the diff end.
Easy 1 hour job, see half shaft replacement threads on forum

 

New CV shaft is $60 from O'Reilly's. Lifetime warranty. And comes with replacement bolts. While you are there, pick up blue locktight to put on the screws so they don't work there way out.

https://www.oreillyauto.com/detail/p...=Show+All&q=cv

While you are there, pick up inner/outer tie rod ends, for the cheap ones you are looking at $19ea, Lifetime warranty.

https://www.oreillyauto.com/detail/p...=Show+All&q=cv

https://www.oreillyauto.com/detail/m...&q=tie+rod+end

And have the thing aligned.

 

Jerry rigged it back together for the time being. popped the head off the axle and have that bolted in so it is still drivable withought the hub killing itself. I believe the bolts are snapped inside the diff. Got any tips to extract them? or should i just hope for the best using a extraction kit... never have luck with them lol