Ford Explorer Axle Swap
I am an average 4wd guy, and not a mechanic. Here I will try to show the process of doing a pretty striaght forward axle swap. Done in a garage at home, and with basic handtools.
Things I have learned doing this swap:
1. Don't try and pick the axle up yourself, it is heavy
2. If you order an axle new, you will need a breather tube (Ford Part # F5AZ-4022-BA), rubber brake lines, (brake line part numbers are Napa numbers, but any parts store should be able to cross reference them as well to a Raybestos or other manufacturer. I used two #380528 and one #36537. The first # is for the caliper hoses, the second one is a long "T" that connects to the framerail steel line) and 3/16" steel brake line
3. Mount the spring perches at an angle, and improve driveshaft angle
4. Banjo bolts for an Explorer can only be obtained from the dealer, and even they have to order them. They are 10mm X 1.0 Pitch, NOT 3/16" Ford Part # 385116-S2
5. Order a good set of shackles, the stock ones will be ruined trying to remove them. I ordered mine from M.O.R.E.
6. You need a Hi-Lift jack and a good floor jack, and good tall jack stands.
7. If your Wrangler sags in the rear (like most seem to) take the springs to a spring shop and have them add a little arch. I brought mine to Zenith Spring, and they were done in a couple of hours for $79.00
8. Mountain Offroad Enterprises makes a good kit with perches and shock mounts, and also sells Spicer adapters for the driveshaft
9. I had the shock mounts welded on, and they were to far down the axle tube, so the shocks wouldn't fit (they hit the axle tube). I recomend Welding them on after the axle is in the vehicle
More pictures to come when I get farther along. I want to have this to the driveline shop to have the front gears swapped over to 4.10 sometime next week.
Notice the difference in axle tube beef
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