I'm going to swap my front differential carrier assembly and was wondering if anyone who has done it before has some pointers of things that stuck out to them.

I originally was going to only replace the differential gears, but the sucker is leaking so bad and a whole used carrier assembly is cheap and easy to get. I'm only aware of a single YT video that shows the process and I have a couple of rapid fire questions.

Is it mandatory to remove the front CV axles from the hubs to pull the carrier or can I just unbolt the connection?
Is there a specific order of operations that will prevent issues?
How heavy is this sucker going to be?
Is it doable with one person or is a partner needed?

 

No one has responded, but I thought I'd throw out an update. I purchased an entire front differential carrier assembly with axles installed from a junkyard for $180. I took the cover off on the bench and cleaned out all the old oil and small metal that had settled to the bottom. I cleaned up the gasket surfaces, filled it up with oil and slapped some new permatex on it. It's prepped and ready for install, so I figured I'd check back in and see if I got any advice on the swap. Looks like it's not a commonly replaced item by the average Joe on here. Maybe I'll submit a write up after it's all said and done.

 

I have not done one on the F150, but I did on my dad's 2004 Explorer Sport Trac. Those have a splined cv axle, so I had to take apart the spindles to get clearance to drop the differential out. I put in a used one as well, and did the servicing of new seals and the like on the bench. I had an extra set of hands to put it in place.

I would hazard a guess that the flat flange with bolts would be easier to gain clearance, since when you jack up the front the cv axles will be pulling out a bit, allowing you to compress the joints in them.

There used to be a dealer service manual online for all Ford in this era, and I haven't looked for it in a while, but it was a real big help for stuff like this that isn't as common.

 

Wasnt too bad of a replacement! It took about 6-8 hours total and there's one YT video that's incredibly helpful. Everything can be done solo except for lifting the new carrier/diff/axle into place required a second person for about a half hour. I bet a shop would charge around $1k for parts and labor on it.

The CV axles being flush mount is convenient and simplified the removal. You don't even have to take the wheels off. Theres 1 single hanger bolt of the 3 that is a royal pain. It's the highest mounted hanger and can only be reached by lowering the steering rack a couple inches and disconnecting the steering yoke under the hood. You have to connect about 18 inches of extensions and then you can reach it from the front by the radiator.

It's not that tough of a job especially if you have a decent impact and electric socket.