Thanks Les! I didn't mean to pull the inner shaft it just decided to come with the cv axle, I will try and throw it all back in when I get home soon without pulling the housing off and let you know how I make out. Hopefully, it doesn't give me too much trouble!

 

You may want to start it up (for vacuum) with left tire on the ground and make sure front axle engages/disengages after installing the axle into the housing, but before putting all back together. Don't take transmission out of park, though. Just see if you can spin the right axle shaft in 2WD but not in 4WD. I worry about 7, 8, 9, 10 being out of place.

 

Thanks Les, I had the same idea. But was going to check after I had everything together, good thing I just checked because something is definitely wrong. I had both front tires off the ground and driver side blocked off and could spin the pass cv axle, there was a distinct clicking feeling. The front axle doesn't lock in, time to pull the housing I guess.

 

So I noticed this while taking the cv axle out but really notice it now. My front diff fluid is very grey like it has water in it, it was also low (from seal leak), but I got a better look after getting the actuator off and the fluid is very grey. Replaced fluid a bit over 10000km ago, I definitely go through a lot of puddles on the trails and I'm thinking water could have been getting in then through the seal. The breather tube also looks good.

Back to the main problem, looking down the housing I can see I have messed up what looks like a washer and it's bent nicely into the inner gear (pictured). Now I didn't mention part #7 in my post above (referring to the diagram above) because I believe that is the retaining ring that's on the shaft. It looks like they have the same thing on the outer splines where the cv axle goes which makes sense. Looking at the picture below and the diagram above I believe that crushed piece is either #8 or 10, most likely 10 though as it looks like 8 has something to ride on #9, and #10 looks like it doesn't have anything to ride on but the shaft. Will see tomorrow what's going on, should also be a lot easier to install the shaft with the housing out of the diff since I can just take the retaining clip off and slide it back on the other side of the housing without the need to hammer it in or anything. The cv axle and inner shaft are also still together so I'm thinking I will put it together like this and once it's done on the bench it will be fully ready to go with everything all seated, then I can get a helper to hold the cv axle out of the way while I bolt up and seal the housing.

 

I believe you have to take 22 (the front axle actuator) out to get the housing off. But maybe not. I would look that up in the factory manual if I was you.

 

Thanks Les, I already got that actuator off and ready to pull the housing. Just need to clean up the last 4 bolts after work and it should come right out. I ordered a whole washer kit from rockauto to be here Monday it says (paid $100 shipping and originally said delivery was tomorrow but I think I ordered like 5 mins after the deadline ). Oh well, just another example of my luck on this job. How does that saying go again, oh right "if it wasn't for bad luck, I wouldn't have any luck at all". Following that I just ordered a new dust shield backing plate as I folded mine with a few blows from the hammer while breaking the lower bj off, it was rubbing the rotor and I was going to try bending it back a bit but with the way this job is going, I'm not leaving anything else to chance here. Will pull the housing after work and give an update.

 

It's just normal headaches for working on cars!! We all go through it!

 

Thanks for the kind words Les, I have heard what you are saying about being a technician and ending up with unpaid diagnostic time. Mainly hear Scannerdanner talk about it in his videos, I'm glad it worked out in the end for you though.

So I pulled the housing today and all looks good, it's just that thrust washer that got caught up. I could probably put it all back together right now as the washer isn't very damaged at all but since the new parts are on the way already I will just wait. In the meantime I will figure out the threads on my cv axle, they got a bit damaged hitting the axle in yesterday even with the nut flush up to the end of the axle. I may try and get an M24x2 die or go down to a fastener shop and maybe have them clean up the threads quickly. Not sure how I will fasten the axle in a vice yet though, still thinking about that. Before I go the die route I may also try angling the end with my bench grinder some more, but I have already done that and the nut will thread on a little bit then get stuck. Thinking it may just be easier to get a die on it and clean it up.

 

Zack, I would caution you about pounding the axle in by hitting on the nut end of the entire assembly. What was done to that washer could happen internally to the CV joints - same forces involved. I worry about your new axle. Sorry but if it was mine and I was going on a long trip I would just bite the bullet, learn from the experience, and get another axle assembly. The threads are already screwed up on it anyways.

When you go back together, you should be able to just start the axle on the shaft and then grab hold of it with both hands and shove it in all at once through the seal. If you need to tap on something. try putting a a couple of big hose clamps tightly (right next to each other) on the inner CV joint body and catch the adjustment screws with a 2x4 - then pound on the 2x4.

Hope this helps.

 

This all reminds me of a job I once did on my own vehicle back when I was 21. A 1965 Ford Galaxy back in about 1977. We had a shop night once per month at a dealership where technicians could bring their vehicles in and work on them. I really liked this old car which was in really nice shape and I wanted to change transmission fluid on the old girl. What a mistake. Got a transmission filter/gasket for a C4 and unfortunately that was not the transmission in the vehicle. Of course I didn't check the fit until I had scraped off the old transmission pan gasket. No parts stores open past 6 in small town and it was a Ford in a GM dealership, so I put it back together as best I could with that good old GM RTV sealer and no gasket so I could drive home. Needless to say, it leaked. It leaked so much that night driving here and there that it ran the trans dry enough to start to make it slip and I limped home with it slipping. So next day I hitched a ride to work, talked my dealership into giving me another shop day that night, and after work I put enough fluid in to get it back there the next evening. Put the right pan gasket on and filled it up with trans fluid - but discovered trans was now leaking severely out of the front pump seal. Borrowed a vehicle from used cars to get home and begged another shop day. Took transmission out and discovered the lack of lube had toasted the converter, the bushing in the front pump, and the front seal. The next evening I replaced those three parts and stuck the transmission all the way back in - but it wouldn't internally turn to line up the u-joint when installing the driveshaft - was locked up solid. So I took the trans back out of the car and pushed it outside. Next morning I talked to transmission man at the dealership, and although he wasn't a Ford man, during lunch he helped me discover that I had not stood the trans on it's tail when removing the front pump and several little washers/spacers had fallen out of place. Then when I bolted the front pump back on, the transmission was locked up. Got some washers for my trans from the Ford dealer. So that night I stood the trans on it's tail in a rig the trans man had, and replaced all the washers that had fallen out of place - then installed the trans. No leaks and no noises - but after that day you had to warm up the transmission on a cold day for 5 minutes in order to go into gear to back up. So you learn to park in places where you don't have to back up. Kept that car for another year or so and sold it to a friend with trans still that way. Hope this gives you some amusement and makes you feel a little better about your current repairs. It's the only transmission that I have even been into! Have hated the thought of doing transmission work since then.

p.s. I wouldn't show your mom the white bath towel you laid your parts on! Need to ditch the evidence!