Noticed a low grinding/rubbing sound from the back end. I removed the cover to the rear end differential and found a 1"x 1/2" piece of metal, it appears to be a tab? stamped 025?

Asked by Jun 20, 2017 at 06:22 PM about the 1995 Ford Explorer 4 Dr XLT 4WD SUV

Question type: Maintenance & Repair

I rotated the tires and looked at all the gears and did not notice anything
damaged just normal wear.  How can I locate where this tab may have come
from?

7 Answers

27,495

SEND A PICTURE..SOUNDS LIKE THE TAB FROM OUTSIDE 1 OF THE COVER BOLTS???? PINION BEARING? DID YOU REFILL IT WITH 90WEIGHT GEAR OIL? ANYWAY PULL BOTH BACK TIRES AND LOOK AT THE BRAKES ALSO HOW ARE THE U JOINTS

I took the part in question in to a mechanic, they indicated it was related to the Limited Slip Clutch. They feel it was a tab that wraps over the bolt/nut.

Hi Kelly thanks for your response. I've included the pic. After cleaning debris from inside the rear end housing I filled it with 80W 90 gear oil. I did jack the truck up initially and checked to see if I had any play, none noted. With the ties removed I would say I have 1/8" play in/out which I can see the brake calipers move. I have not looked at the U joints yet.

20,410

Are you sure it came from within the inside of the differential? There should be a similar tag attached to one of the bolts on the outside. The number on the tag is the ratio of the rear end. Maybe 825 and not 025?

When removing the differential cover/bolts I removed one tag with many numbers on it. I cracked open the cover to drain the fluid, then pulled the cover off and the item fell out. You can see it got hit by the gears. The mechanic indicated it belongs to the slip clutch assy.

After looking at the Limited slip clutch pack the shims do have tabs I also noted someone had found two tabs that sheared off and were in the bottom of the rear end housing. So when I eventually tear mine down I will see if this is my case. I'll make sure to update this forum.

After disassembling the rear end I found damage to the Pinion gear, the Spider gear washers severely worn, damaged Pinion, and broken Carrier shims probably due to a rear end collision. I didn't have the specialty tools for a precision rebuild so elected to pull the same type of rear end from Jalopy Jungle. Cleaned & Lubed and verified operation. Happy to say it works great! Spent just a tad over $300. 1995 Ford Explorer lives!

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