buying a used 3.73 front diff, missing some vac disconnect parts

[98eb5.4]

front diff is shot, 4X4 never worked worked in the last 5 years & i'm getting to it now

a few years ago, i noticed the pax side inner axle had lotsa play on it, in that you could pull it away from the (#15 top pix) diff extension housing (~ a foot long) piece on that side of the diff, quite a bit, like it wasn't secured properly, this when it was all attached in the front, cv axle & everything,

started to get some random serious noises there so started by pulling the pax side cv axle, then, discovered at some point a crack in the (#15 top pix) extension housing at the bottom corner where the flange bolts up to the diff by 4 bolts

it ended up coming off in 3 pieces, i figure the securing circlip for the inner axle at some point came off/broke, allowing excessive left right movement of the inner axle eventually stressing & cracking/breaking the housing where described,

so got a used front diff but some parts were missing that are shown & described well in this post
4wheel drive, front end not engaging (?) - F150online Forums

"In the top picture #10 pushes #25 and that ( look at bottom Picture ) pushes #13 and that slides #14 over #15 and (top picture) #11 to lock them together."

parts missing (or not there) on the one i received are (1st or top pix in link)
#10
#24
#25

then in the second, or bottom pix
#18

anyone know if part #18 (lower pix) can be added from the outside? without taking off that foot long pax side inner axle extension housing (#15 top pix)?

looks to me like part #18 is secured by pin #17 (bottom pix) & housing part # 15 (top pix) has to come off to secure the pin for #17, #18 & #13 (front axle drive shift fork)?

 

[98eb5.4]

had another look at the used diff & looks like the pin goes in from the outside but prob have to go in to locate/align the parts, gonna take some pix,

main reason i needed to know this first is when you get a part from a wrecking yard, often you void a warranty if dismantling,

anyone know for sure?

 

[98eb5.4]

pix

 

[98eb5.4]

looks to me like someone tried to get part #!8 out (you can see 2 gouge marks near the hole, 2nd pix above) without pulling the retaining pin which is still there,

and that's how part #18 (front drive axle shaft shift lever) broke, it's supposed to stick outa the casing to attach the rest of the actuating parts,

might be deal with the pin & the shaft slides out, i'll know for sure eventually

good vid on what wears out in there
https://www.youtube.com/watch?v=cBcJ5FDhoCE

F75Z3N139KT | eBay

 

[98eb5.4]

pretty good thread here 'cept sez u drop the diff
2003 8.8 Front Differential Shift Fork Replacement - Ford F150 Forum

2003 8.8 Front Differential Shift Fork Replacement - Ford F150 Forum

with diff in place
Writeup: Replacing / Repairing the CAD (Center Axle Disconnect) - F150online Forums

8a. If the shift fork shoes have been broken off, most likely the short axle and connecting collar will come out when you drop the housing (this is important during re-assembly).

<snip>

10b. When replacing the fork, you can drive the pin out of the original fork. There is clearance on the backside of the fork to allow the pin to be driven through.
10c. Pull out the fork and replace the o-ring on the shift lever before reinstalling.
10d. When installing the new fork, be sure to put the locking collar on the fork before installing it in the differential (it may give you trouble if you install the fork and then have to force the locking collar into position).
10e. With the new fork and collar in the differential, now install the short axle shaft through the locking collar and on into the differential. (I learned the hard way and figured out it’s much easier to align the short shaft with the locking collar and the gear in the differential first and then just align the smooth shaft with the axle shaft in the housing when re-installing the housing.)
10f. Before installing the housing, the Dorman kit comes with a new snap ring for the axle shaft that remains in the housing. I didn’t understand why they sent this too because I didn’t have to disassemble the axel that remains in the housing, but upon investigation I noticed my original snap ring was stretched/warped so I went ahead and replaced it and it fit perfect.

 

[98eb5.4]

ok, bottom line, the pax side axle/housing does have to come off, to pull out part #18, which is the (Front Drive Axle Shaft) shift lever assembly

4wheel drive, front end not engaging (?) - F150online Forums

 

[98eb5.4]

need to pull the front driveshaft then the front diff (cv axles are out),

not clear if i can drive around after pulling the front driveshaft?

mainly i guess will transfer case oil leak out without the front driveshaft in place (connected to the transfer case) & connected to the front diff?

need a few days sorting out a front diff, prob have to use some parts from the one in the truck (after i pull it) & wanna be able to drive in the meantime

 

[98eb5.4]

something new for me, DO NOT pull the cv axles, then drive that way!!!!!!!!!
https://www.google.ca/search?q=f150...dHYvb-QHrw4QI#q=f150+driving+without+cv+axles

at least for 97-03

it can quickly destroy a front wheel bearing

 

[98eb5.4]

got the front diff out yesterday, one person driveway job doable with 2 jacks,

rigged up some 1" bolts to secure the front wheel bearings,

should also mention that driving without the cv axles can result, without any warning, in as the bearing lets loose quick, instant wheel lockup,

i got real lucky on that one and not much in the way of collateral damage, i've seen broken/cracked discs as a result

there's a good vid out there but can't find it,

strangely enuff, the right side was ok for ~ 1 wk after i took that axle out first, left side bearing broke on the first drive/trip

 

[98eb5.4]

with all the info out there sayin no way ls clutch deals for the front

gotta wonder why a quick check at randys
RANDYS Worldwide | Differentials, Rear End Gears, Axles, Lockers

brings up this 1? (of 2 options)
Diff Wizard suggests Trac Loc positraction for Ford 8.8" with 28 spline axles. Will fit IRS and IFS - SVOM4204F288

SVOM4204F288 $425.43

Trac Loc positraction for Ford 8.8" with 28 spline axles. Will fit IRS and IFS
Trac Loc positraction for Ford 8.8" with 28 spline axles. Will fit IRS and IFS. The Trac Loc is a less aggressive, street-friendly limited slip suitable for daily driven vehicles and mild off-road use. This unit uses clutches and is Rebuildable. All units come standard with a one year warranty against manufacturing defects.

Technical Notes: This unit will work in differentials with independent front or rear suspension and does have the provision for an ABS tone ring.

including

Compatible Differentials
Ford 8.8" - 28 Spline
Ford 8.8" IRS Passenger Car 28 Spline
Ford 8.8" Reverse Front 28 Spline

Compatible Make / Model
Ford Crown Victoria (1983 - 2011)
Ford Expedition (1997 - 2008)
Ford F-150 1/2 Ton (1997 - 2008)
Ford F-250 3/4 Ton (1997 - 1999)
etc

 

[98eb5.4]

so, adding info for anyone else who may be doing this job/work for the first time

can't stress enuff, DO NOT PULL THE FRONT CV HALFSHAFTS/AXLES AND DRIVE THE TRUCK THAT WAY!!

shoulda checked first but took the pax side axle out first and no issues in 1 wk of daily driving, thought from that a-ok

on the driver's side, same type bearing let loose suddenly & without warning locking up the front wheel, within 10 min on the a first drive after pulling the cv axle on that side

a new bearing (differently designed from the above 2) got loose just from moving the truck a few times in & outa the driveway,

you can however drive without the cv axles but then must secure the front wheel bearings by some alternative suitable method

after the diff comes out, there are then front driveshaft decisions to make, i thought i could just support the disconnected front part and be ok in 2wd (NOT ALL HAVE THAT OPTION)

so used a wire coat hanger for testing and quickly found out that even disengaged, the front driveshaft will spin up so (doubt much needed to stop the spinning but) needs to be dealt with or considered for with whatever or in combination with methods used to support it,

fuses need to be pulled so the 4x4 selector switch (right next to the heater fan switch that is identical on mine) doesn't work, to prevent accidental engagement

the other option but way more involved is full removal, here's a few threads (best to read all of it)
Front Driveshaft Removal - Ford Truck Enthusiasts Forums

A4WD front drive shaft - F150online Forums