Not so Good Vibrations

[whtbronco]

More pics tomorrow. That bushing or seal, it's rubber, fell out of the output shaft housing. Clearly it goes on the output shaft splines. I suspect the chain slack is reduced a bit when the rear case half is on, but how much is too much?

 

[SafariGoneWrong]

You've done a great job helping out the community of us 4WD Expedition owners. I'd do exactly what you're doing to get it back on the road soonest. And you retained the original versus sending it in as a core, as I'm a believer whatever is on my vehicle is probably in better shape than whatever basket case a rebuilder received. Looking forward to pictures, oddly curious about what Ford calls the "gearmotor encoder assembly".

 

[whtbronco]

I too worry about the parts that were received in a core and then "checked" in a reman unit.
Hmm, "gearmotor encoder assembly" all I can think of is the planetary, but it seems unlikely.

 

[whtbronco]

Here's what I think are useful and/or important pics. I have 57 to upload, 5 per post.

 

[whtbronco]

Starting internal disassembly.

 

[whtbronco]

Continuing internal disassembly.

 

[whtbronco]

Continuing internal disassembly.

 

[whtbronco]

More internal disassembly.

EDIT: On my 3rd attempt to locate the 2nd washer for the thrust bearing I found it seriously stuck to the front side of the rear chain sprocket. The picture only shows 1 washer, but there's pretty much always supposed to be 1 on each side of a thrust bearing.

 

[whtbronco]

And yet more internal disassembly.

 

[whtbronco]

Still more internal disassembly.