Ford Super Duty (1999-2016) :: 2001 - One Loud Bang / Thud In Front Axle Area When In 4 Low


Oct 19, 2015

We were using my 2001 7.3 4x4 (automatic, manual lock outs) in 4 low yesterday on dry pavement in an attempt to pull out the remainder of a 6x6 post in concrete. We were working her pretty hard alternating directions of pulling. At one point we heard a loud bang (see also: thud; pop; etc). It seemed at that point that the front axle was no longer functioning in 4wd. We still had the low gearing feel, but at one point I noticed my rear tires trying to slip on the driveway, but fronts didn't appear to be pulling anymore.

Long story short, came in, went to bed, went out this morning and thought I'd jack up the front end and roll the tires in both 'free' and 'lock' to see if the universal joints (yokes?) behind each wheel were spinning or not, depending on whether free or locked in. I noticed on the passenger side a few drops of a clear/light colored fluid that had dripped from behind the dust cover that isn't functioning any longer. The joints worked as they should, based on if it was locked in or not.

I decided to go ahead and put the back axle on jackstands as well and see how it was working when "driving". When in 2wd, rear worked, front was stationary, as it should be. when in 4high, rear spun, front driver spun erratically, nothing from passenger front (where I had seen drip). 4low was same thing - erratic on driver side, at best.

So I know I have front axle/transfer case issues. The question is, with the drip (smells like grease, so I'm assuming its gear oil?) would I be safe to drive it a few days with hubs in free position? I don't want all of the fluid leaking out when I'm driving down the road. I use the truck for work and wouldn't be able to be without it until later in the week or next week. But I also don't want to drive it if it will just make my predicament worse.

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I was driving, Iput the brakes on then suddenly I heard a loud bang and brake pedal went all the way to the floor. I knew there was something wrong with the brakes, parked went and checked the passenger side rear brake caliper was ripped off which made a hole through my rim and also ripped off the brake lines. I need to get the part but I don't know what its called. See the pictures....

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What would be the likely causes and how much would a typical repair/replace cost?

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I noticed the other day after my truck was parked on a bit of a angle there was diff oil from the passenger side on the ground. reading a bit on here i learned the axle seals are way in the front housing close to the front diff. and yesterday driving a heavy load around my front brake driver side got stuck on a bit and over heated and was smoking, couldn't even touch the rim it was so hot. anyway about this axle seal i got the hub off right now but cant seem to pull out the axle assembly through the knuckle but i see i have to pry and most likely wreck that seal. Looking for a link of piuctures or how to replace the axle seals in the housing.

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I noticed when checking out the passenger side front axle at the u-joint that I was able to spin the whole u-joint and bearing with the wheels still on the ground. I wasn't able to do the same for the driver's side. Both hubs were set to auto although I know that the ESOF doesn't work. Is this normal? Am I supposed to be able to spin the axle with the wheels on the ground?

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