I have a 2014 5.0 and I recently replaced my oil pan gasket. A couple days later I noticed a noise when turning and realized my front diff mounting bolt was coming loose and hitting the steering rack. I took the 18mm bolt out, and the threads are fine on the bolt but the inside of the diff had a ton of metal shavings.

My first question is, I'm driving 800 miles in like 3 days, can I drive with only 2 of the mounting bolts in if I don't engage 4x4?

Secondly, how do I go about repairing this? Locktite isn't an option as the threads are gone inside the diff, and no shop will touch it unless I take the diff off and bring it in. Is there any advice on repairs or a link to a forum post on removing the front diff?

Thank you

 

Can you install a heli-coil to replace bad threads?

 

Not really, I don't have the tools to drill the hole bigger. That's what I asked shops to do and they all refused except one that will do it if the diff is taken out.

 

Perhaps I'm remembering incorrectly, but aren't all the threads in the frame and not the differential housing? I would think you could helicoil the threads on the frame, remove the captured/welded nut from the frame and replace it, or use a longer bolt and nut to go past the damaged threads.

 

That's my first time seeing the diagram, but yes you are correct. I'm referring to the top left photo in the diagram and have the bolt removed already. Theres no threads left at all in the frame as i can just pull it straight out. I've never used helicoil or rethreaded anything for that matter, what would I need to use helicoil?

Thank you

 

Am not clear where these stripped threads are. A HeliCoil may or may not be appropriate or the best idea in this case. If SALEEN961 suggested longer bolt and a nut idea will work that sounds quick and easy.

YouTube has lots of videos to see how to install and ideas where HeliCoils can be used to repair or even prevent stripped threads.