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2003 Expedition Front passenger side axle falling out differential????

Discussion in '2nd Gen - 2003 - 2006' started by Eightiesrock80, Sep 19, 2020.

  1. Eightiesrock80

    Eightiesrock80 Full Access Members

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    I was replacing the cv axel and when bolting in the cv axle I noticed it pulled right out so I pushed it back in. I was reading on google and people are saying the snap ring or c clap must have fallen off the end of the axle inside the differential were all the gears are. Is it going to be hard to get this clip back on the end of the axle??? HELP!!!!!

    1B04DC8E-0830-4605-BDD2-357B76C8A80D.jpeg
     
  2. Hamfisted

    Hamfisted Full Access Members

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    If you don't have the '03 Factory Service Manual you can download it free here: https://spaces.hightail.com/space/hoVVsN5P2A


    If you're lucky it's just a broke snap ring and you can push it back together and insert a new snap ring. Look on page 427 of the service manual for a blow up diagram of the front axle and instructions.

    If you want to go ahead and buy a new snap ring they have 'em at the dealer or you can find them on eBay. It looks like it lost a lot of gear lube, so inspect the whole ring gear for damage, and refill the axle with lube when you put it back together.

    https://www.ebay.com/p/1627119314


    Ford part number N808765S
     
    Last edited: Sep 19, 2020
    Lee_H and Eightiesrock80 like this.
  3. Eightiesrock80

    Eightiesrock80 Full Access Members

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    so that picture is from online it’s not actually my truck but it’s the same exact problem. Only mine isn’t leaking anything at all. Thank you so much for your time. I’m going to look at that page now


     
  4. Hamfisted

    Hamfisted Full Access Members

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    If it looks like that it should've been leaking gear lube. Or maybe that's what caused the snap ring failure. It didn't have enough lube in it to begin with. When you put it back together make sure to fill the axle to the proper level with new gear lube.
     
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  5. Eightiesrock80

    Eightiesrock80 Full Access Members

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    No idea how to start
     
  6. Eightiesrock80

    Eightiesrock80 Full Access Members

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    Can anyone tell me how to replace the c clip
     
  7. Eightiesrock80

    Eightiesrock80 Full Access Members

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    That files not working
     
  8. Hamfisted

    Hamfisted Full Access Members

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    The service manual download works fine. I think you need to take the Expy to the shop.
     
  9. Eightiesrock80

    Eightiesrock80 Full Access Members

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    I did
     
  10. David E

    David E Member

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    Hi there... Any chance you have a link for a 2005 Expy manual? thanks in advance.
     

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