Seldom Used Front Axle / Rebuild

[DSJW]

It's time to tackle the front axle and rebuild/replace/refresh the worn out components. Like many 4x4's my '77 has not seen a lot of 4 wheeling. But, I have also been bad about locking the front axle in and occasionally running it and the transfer case, probably haven't run either in ten years. And before that it was only once a year.

I only want to do the front axle once, and I'm going on the assumption/hope that all the gears in the differential are good as they have seen very little use. So I will be working from the axles out. Looking for suggestions or guidance on whether I should run the front differential before rebuilding, or would it be better to pull it apart as it sits, unturned, and look for rust.

I have owned this Bronco for around 25 years, it is driven weekly, around 2500 miles per year, and as far as I know the front axle has all original parts. Besides seals, u-joints, bearings, what else should I do when I'm in there? I'm thinking that ball joints at the same time makes sense. What brands are good solid/strong replacements? Don't need Super-Duty stuff, but definitely worth buying high quality parts. I'm sure I'll have more questions.

Thank you all for your help!

 

[Broncobowsher]

Change the oil, grease the zerks, keep driving it.
If a seal starts leaking, change them all at once. Nothing else needs replacing. Good chance that the replacement parts you are looking at sourcing are not as good as the originals that are probably still in perfect shape.

 

[blubuckaroo]

Plan on changing the axle needle bearings.
mine were good after 200K but most are dust.

 

[DSJW]

The driver side seals are leaking slightly, the u-joints have never been greased, there was a "klunk" during a hard turn the last time it was in 4wd, and there is an odd, but quick, veer to the right under certain circumstances when driving. It is TIME to work on the front axle and suspension. I hear what you are saying about the quality of parts today, and that is a big concern, and a big part of my question.

 

[palton67]

A Klunk and veer for me was a broken/binding U-joint up front, time to take a real close look.

 

[knack]

A Klunk and veer for me was a broken/binding U-joint up front, time to take a real close look.

X2 on the u-joint. Can make for real exciting unplanned lane changes.

Good that you'll be taking it apart, at least that far.

I'd also want to make sure wheel bearings are still OK. Hopefully no need to replace anything there other than seals, after a good cleaning and greasing.

If the differential fails, you can unlock the hubs, shift into 2WD and keep driving. A failed wheel bearing or a frozen u-joint are a lot more dangerous on the highway.

 

[DSJW]

Does anyone have recommendations for good quality brands for the u-joints, ball joints, seal kits, etc.? Do any of the vendors sell outstanding products or kits? Thank you for any info or suggestions you might have.

 

[Justafordguy]

Only use Spicer for the U-joints.
Moog makes a good ball joint but I've had good luck with Raybestos also.