While baselining my '71 today, I found this...

[4via4]

After taking the front diff cover off to change the oil and replace the gasket, I started having chunks fall out of the housing. Upon further inspection, it turned out to be metal chunks and a lot of them. I need advice as to how I should proceed. I assume now is a good time to upgrade to a Dana 44, but would like your opinions and answers to:

1. How did this happen?

2. Other options other than replace the front differential?

3. Is replacing a DIY job with hydraulic jacks, etc.

4. If replacing with a D44, anything else to do while I'm in there?

Thanks for taking the time to read the post and your opinions.

 

[sykanr0ng]

After taking the front diff cover off to change the oil and replace the gasket, I started having chunks fall out of the housing. Upon further inspection, it turned out to be metal chunks and a lot of them. I need advice as to how I should proceed. I assume now is a good time to upgrade to a Dana 44, but would like your opinions and answers to:

1. How did this happen?

2. Other options other than replace the front differential?

3. Is replacing a DIY job with hydraulic jacks, etc.

4. If replacing with a D44, anything else to do while I'm in there?

Thanks for taking the time to read the post and your opinions.

1. Deflection kills gears.
There was stress put on the housing which moved the ring and pinion gears farther apart then they slammed into each other.

2. You don't mention what you are going to be using the Bronco for.
A Dana 30 is adequate for a street use Bronco.
A Dana 44 is a much better choice if it will see use on any but the mildest trails.

3. It can be done but you will probably want help.

4. Upgrade the axle shaft U-joints, the Bronco ones are well known to be weak.

 

[redwards69]

Yikes! That's not good.

 

[savage]

Man that's not good. That's one thing I have not checked in a long time, time to open her up.

 

[DirtDonk]

The even worse news is that it looks like you have the much sought after Dana/Spicer Powerlock limited-slip differential too!

I agree with sykanrong though about your intended use. A 44 is wasted effort and money on a street rig with smaller tires that's only going to see casual and intermittent use for fun with the family.
And even off the highway, if you're not hard on your equipment and still don't have big tires, refurbishing your 30 is a legitimate solution.

And in case you were wondering, there is only one 44 that's a drop-in, and that's one from another EB. Other than custom then, your only choice is to find one from a Bronco.
Good luck either way. Sorry you had such a rude surprise when you opened up the cover to do maintenance.
Lots of people don't do that simple maintenance. Which might actually lead to things like this!

Paul