2013 Explorer Interceptor Repairs

Discussion in 'Explorers - Expeditions - Excursions - Broncos -Es' started by Roush PSD Interceptor, Sep 15, 2019.

  1. Roush PSD Interceptor

    Roush PSD Interceptor Straight Piped Diesel Staff Member

    Age:
    54
    Posts:
    9,646
    Likes Received:
    512
    Joined:
    Nov 28, 2010
    Location:
    Ringgold, Georgia
    Took it in to Ford of Dalton for recall 19E02. Reprogram ECU for catalytic converter CEL code P0402 Catalyst Inefficiency. They did the reprogram and replaced both manifold cats on the 3.7L Cyclone engine at no cost.

    Sent from my SM-G973U using Tapatalk
     
  2. Roush PSD Interceptor

    Roush PSD Interceptor Straight Piped Diesel Staff Member

    Age:
    54
    Posts:
    9,646
    Likes Received:
    512
    Joined:
    Nov 28, 2010
    Location:
    Ringgold, Georgia
    While it was there, my wife wanted to save me some labor since my doctor gave me handicap plates and quote fixing the leaking rear diff.

    Had been using about 4 ounces over 100 mile trip.

    Call came back @ $1,200 to reseal the leaking diff cover.

    Sent from my SM-G973U using Tapatalk
     
  3. Roush PSD Interceptor

    Roush PSD Interceptor Straight Piped Diesel Staff Member

    Age:
    54
    Posts:
    9,646
    Likes Received:
    512
    Joined:
    Nov 28, 2010
    Location:
    Ringgold, Georgia
    Told them I would take care of the leaking diff cover and the
    service writer came back saying the entire differential had to
    be removed from the vehicle to "split the case" reseal it and
    reinstall back into the vehicle.
    I would need a service lift to
    accomplish this and did I have one? I told him I could do the
    diff work just to finish the recall.

    After getting it back home, I found the diff cover wasn't leaking.
    It was the drivers side stub axle seal. Not even wet at the back
    from the diff cover.

    While waiting for them to finish the recall work and cats, I ordered
    a whole used diff from ebay for $140 shipped with 71K on it.

    20190909_142114.jpg
    20190913_141842.jpg
     
  4. Roush PSD Interceptor

    Roush PSD Interceptor Straight Piped Diesel Staff Member

    Age:
    54
    Posts:
    9,646
    Likes Received:
    512
    Joined:
    Nov 28, 2010
    Location:
    Ringgold, Georgia
    So come Friday August, 30th, no call from Dalton on the
    status of our repair. The service writer said he had called and left
    a message it was completed two days ago.
    Nope, Wednesday afternoon, the 28th,
    you called and said a rusty bolt was holding up progress on the exhaust
    manifold.

    So I also decided to change the diff lube in the front PTU while at it.
    This is when I found shoddy reassembly work.
    One bolt missing and one bolt finger loose. Two blind nuts finger loose
    one the backside of the exhaust flange bracket of the front catalytic
    converter downpipe to transmission bracket.
    Image 1 shows no turn marks on bracket. No bolt was ever inserted and torqued
    like it does in Image 2.
    Image 4 shows the side to side movement chaffing in just 12 miles of driving.

    Bracket 1.jpg
    Bracket 2.jpg Bracket 3.jpg Bracket 4.jpg
     
  5. Roush PSD Interceptor

    Roush PSD Interceptor Straight Piped Diesel Staff Member

    Age:
    54
    Posts:
    9,646
    Likes Received:
    512
    Joined:
    Nov 28, 2010
    Location:
    Ringgold, Georgia
    Access plug for draining the PTU.
    Shop manual say to remove front cat, remove the temp sensor shield
    and remove the temp sensor to refill case.
    I found another way albeit slower, less labor. Refill through the vent tube.
    The drips are PB Blaster sprayed on the plug threads.
    Takes an 8mm Allen wrench to fit the plug. Recommend a grease sucker
    to get the remaining fluid out.

    I refilled with Lucas Synthetic 75w140 per manual through the vent tube
    mod found on Youtube.

    PTU plug.jpg
     
  6. Roush PSD Interceptor

    Roush PSD Interceptor Straight Piped Diesel Staff Member

    Age:
    54
    Posts:
    9,646
    Likes Received:
    512
    Joined:
    Nov 28, 2010
    Location:
    Ringgold, Georgia
    On to disassembly of the rear knuckle to replace the stub axle seal in the rear diff.
    First whas remove tire/wheel.
    32mm impact socket to remove axle nut.
    Then remove and toss brake caliper bracket bolts.
    Tied up the caliper and later moved the rope off the brake line.
    Remove sway bar drag link nut.
    All hardware, nuts bolts and screws are toss on this job,
    torque to yield hardware.

    20190911_180154.jpg

    20190912_181805.jpg

    20190912_181836.jpg

    20190912_181847.jpg
     
  7. Roush PSD Interceptor

    Roush PSD Interceptor Straight Piped Diesel Staff Member

    Age:
    54
    Posts:
    9,646
    Likes Received:
    512
    Joined:
    Nov 28, 2010
    Location:
    Ringgold, Georgia
    Next remove the drag link from the sway bar.
    The major mounting bolts and nuts to the aluminum knuckle are next.

    Toe link outer bolt and nut. 20190912_182409.jpg 20190912_182943.jpg 20190912_182948.jpg
     
  8. Roush PSD Interceptor

    Roush PSD Interceptor Straight Piped Diesel Staff Member

    Age:
    54
    Posts:
    9,646
    Likes Received:
    512
    Joined:
    Nov 28, 2010
    Location:
    Ringgold, Georgia
    Remove 8mm head speed sensor screw.
    Speed sensor removed.
    Speed sensor moved out of the way.

    20190912_182956.jpg
    20190912_183209.jpg

    20190912_183213.jpg
     
  9. Roush PSD Interceptor

    Roush PSD Interceptor Straight Piped Diesel Staff Member

    Age:
    54
    Posts:
    9,646
    Likes Received:
    512
    Joined:
    Nov 28, 2010
    Location:
    Ringgold, Georgia
    Upper knuckle mount to swing arm bolt/nut.
    Then the lower shock mount bolt.

    20190911_180249.jpg 20190912_183753.jpg 20190912_183809.jpg
     
  10. Roush PSD Interceptor

    Roush PSD Interceptor Straight Piped Diesel Staff Member

    Age:
    54
    Posts:
    9,646
    Likes Received:
    512
    Joined:
    Nov 28, 2010
    Location:
    Ringgold, Georgia
    Now the axle stub shaft can be pushed from the wheel bearing.
    Go slowly to not damage wheel bearing.
    Used a rag on the CV boot to prevent damage.

    20190912_184338.jpg 20190912_184331.jpg

    20190912_185021.jpg
     

Share This Page