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Booger Re-Gear

From 1996 Ford Bronco “Snot”, documented by flomaster.

27 photos
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1996 Ford Bronco - After getting the front of the truck securely on jack stands, the first thing to do is to remove the hub. 1996 Ford Bronco - Once the hub is gone, and the brake caliper is removed, take your 4-prong socket and remove the nuts holding the wheel bearings in. There i… 1996 Ford Bronco - Don't forget this sucker. It is a small bolt that threads into the spindle from behind. Can't get the spindle off without this being gone,… 1996 Ford Bronco - To aid in spindle removal, I like to tap the bolts that hold in in place out. Less struggle removing the spindle. Lucky for me I had the sp… 1996 Ford Bronco - This is the view with the spindle off. Notice the inner spindle seal--this should be replaced while you have things apart. At this point th… 1996 Ford Bronco - With the axle removed, you can see straight down into the 3rd member (if you have good light). By the book you'll need to do the same on th… 1996 Ford Bronco - Don't forget to detach the vent hose. When you get to the point where you'll swing the 3rd member out, this will cause you some trouble if… 1996 Ford Bronco - Next we remove the two large bolts that help secure the 3rd member to the TTB. There are two, and they are typically not easy to remove wit… 1996 Ford Bronco - With the exception of the uppermost bolt, remove all of these. You'll want to loosen the top bolt enough to be able to swing the 3rd member… 1996 Ford Bronco - With the upper bolt still loosely holding the 3rd member, lift the 3rd member up and drain it. I threaded one of the side bolts back to hol… 1996 Ford Bronco - Now, unless you're Arnold Schwartzenneger, and you feel comfortable swinging this pig around by hand, I recommend that you support the 3rd… 1996 Ford Bronco - Now, once the last bolt is out we can swing the 3rd member away from the TTB and expose the guts. Before we can finish removing it altogeth… 1996 Ford Bronco - Now its time to clean, clean, clean. While you're cleaning, there are a couple of decisions to make. One of them is whether or not to drill… 1996 Ford Bronco - Re-assembly is everything in reverse. Pay attention. If you notice, in this picture I've re-attached the spindle and forgot the dust shield… 1996 Ford Bronco - Rear gears are much less work, although there is additional precision related to it. Maybe its easier for me because I've done these so man… 1996 Ford Bronco - Once the cover is off, this is what you're left with if you have a limited slip differential. An open carrier is not much different. Brake… 1996 Ford Bronco - Before we can disassemble anything, this retaining bolt must be removed. Be very careful, as these have been known to crack. A stress fract… 1996 Ford Bronco - Here is a C-clip in its natural habitat. It serves to keep the axle from sliding out of the axle housing, and normally lives a reclusive li… 1996 Ford Bronco - Push in on both axles to expose the C-clip further. They can then be removed with some needle nosed pliers, or as I did, with a small magne… 1996 Ford Bronco - Circling back to this photo because my phone battery died, and I continued work until my wife re-charged it for me. In any case, there are… 1996 Ford Bronco - Before you can get the carrier out, you'll need to pull the axles out slightly so the carrier can clear them. Be prepared for oil to weep o… 1996 Ford Bronco - Backlash is measured by reading the play between the ring gear and pinion gear. Index the ring gear to one side, and move it all the way in… 1996 Ford Bronco - Now its time to run a pattern on the gearset. Mark the ring gear with marking paint. Marking paint comes in different colors, including yel… 1996 Ford Bronco - The "coast" pattern is only half the battle. We need to check the "drive" side of the gear as well. Again, the lighting makes it difficult… 1996 Ford Bronco - It is HIGHLY recommended to use a new retaining bolt. Unfortunately, I could not find the one I bought so I had to re-use the old one. You… 1996 Ford Bronco - First, let me apologize for the picture quality. My son took these pictures while I was driving, and the road isn't as smooth as I'd like i… 1996 Ford Bronco - In this picture we can see that engine load as measured by the PCM is 39.28. Again, this is roughly a 20% reduction from what was measured…