Tools and Materials:
* Repair Manual: Absolutely essential for specific torque specifications and procedures.
* Jack and Jack Stands: Securely support the vehicle.
* Wheel Chocks: For added safety.
* Socket Set and Wrenches: Various sizes, including metric and SAE.
* Torque Wrench: Crucial for proper tightening.
* Pry Bar: May be needed to remove parts.
* Hammer and Punch (or Drift): For carefully seating components.
* Penetrating Oil: To loosen rusted bolts.
* New Axle Seals: Get the correct seals for your specific axle type.
* New Axle Nut: It's recommended to replace this after removal.
* Drain Pan: For collecting gear oil.
* Gloves and Safety Glasses: Protect yourself.
* Clean Rags or Shop Towels: For cleanup.
* Gear Oil: The correct type and quantity specified in your repair manual.
Procedure (General Steps - Consult your repair manual for specifics):
1. Safety First: Engage the parking brake, chock the wheels, and securely support the vehicle on jack stands.
2. Remove the Wheel and Tire: Remove the wheel and tire from the affected side.
3. Remove the Brake Caliper and Rotor: Carefully remove the brake caliper (support it to prevent hanging from the brake line) and the rotor. You might need to use C-clamps to compress the caliper piston.
4. Remove the Axle Nut: Use a large socket and breaker bar to remove the axle nut. This will likely be very tight. Mark its orientation if you need to reinstall it.
5. Remove the Axle Flange: Depending on your Explorer's configuration, you might need to remove the backing plate or other components to access the axle flange. Your repair manual will guide you here. Separate the axle shaft from the differential.
6. Remove the Old Axle Seal: This is usually done using a seal puller. Carefully remove the old seal, ensuring you don't damage the axle housing.
7. Clean the Axle Housing: Thoroughly clean the axle housing bore where the new seal will go. Use a clean rag and solvent to remove any debris or old sealant.
8. Install the New Axle Seal: The new seal typically needs to be tapped in using a socket that's slightly smaller than the outer diameter of the seal. Use a hammer and a soft mallet to avoid damaging the seal. Make sure it's seated evenly.
9. Reinstall the Axle Flange: Reinstall the axle flange and components removed in step 5.
10. Reinstall the Axle Nut: Torque the axle nut to the specifications in your repair manual. This is critical for proper operation and safety.
11. Reinstall the Rotor and Brake Caliper: Reinstall the rotor and brake caliper. Make sure the caliper slides freely.
12. Reinstall the Wheel and Tire: Reinstall the wheel and tire and tighten the lug nuts to the proper torque specification.
13. Lower the Vehicle: Slowly lower the vehicle from the jack stands.
14. Check the Gear Oil Level: Check the differential gear oil level and add oil if needed. Your repair manual will specify the type and quantity of gear oil required.
15. Test Drive: After completing the repair, test drive the vehicle and listen for any unusual noises. Check for leaks around the axle seal.
Important Considerations:
* This is a simplified overview. Consult a repair manual specific to your vehicle for detailed instructions and torque specifications. Improper installation can lead to serious damage.
* Safety is paramount. Use jack stands, chock the wheels, and take all necessary precautions to avoid injury.
* If you're not comfortable performing this repair yourself, take your vehicle to a qualified mechanic.
This repair is more complex than it sounds. If you lack experience working on vehicles, seeking professional help is strongly recommended. Improperly installed seals can lead to axle damage, leaks, and safety hazards.
