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Certified Ranger Nutjob
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This is something I forgot to cover in all my mass posts yet slightly outlined it...
I have a 2011 with 3.73s, my axle code is 96. Upon adding earlier rear blocks to mine to add some lift I had to order different U-bolts than I got with the blocks. I realized I have the thicker axle tubes (3.25" IIRC), which means 31 spline right? Unless Ford decided to use the thicker tubes with the same 28-spline axles.
edit: I'm interested in going with some 4.10's eventually. It would be nice to find an LS rear end but I think I'll just end up getting re-geared. If I happen to find a decent 31 spline rear end, I should be able to assume the front diff will swap over to mine as well, right? Are there different size/spline front drive axles (CV joints) or were they all the same?
Also, guys looking for LS or a locking diff can likely fit one from a Mustang. The V6 (4.0) from '05-09 had the 7.5" rear end and the GTs (4.6L) had the 8.8". The axle housings will obviously be different but the internals should be identical, given the correct splines.
2010+ TRUCKS (ONES THAT HAVE FACTORY DISCS) HAVE 31 SPLINE AXLES. That means 7.5 or 8.8, both rear ends used 31 spline axles.
2010+ Axles also can not (or at least have not yet) been swapped into an older truck as the ABS setup is different. These trucks instead of a 3 line ABS system (2 front wheels and a sensor in the rear diff) used a 4 way ABS system (one sensor at each wheel) with no spot for a sensor in the diff.
On a similar note, to swap axles into a 2010+ truck from something different (be it Ranger or Explorer) you would also have a few issues to fix. I personally think the easiest axle to swap in would be the 31 spline FX4 axle I ranted on for multiple posts in this thread as the only thing needed would be to change the orientation of the brake mounting brackets and then swap on the stock disc brake setup to keep a working ABS system. Next easiest would be an Expo setup as you have to do that and then do what you normally have to for swapping that axle into a Ranger.
As for a LS setup, I would personally set out to find a 2010+ truck rear 8.8 (it is surprisingly easy between Ebay and local yards to find a decent priced one that needs minor work) as the 8.8, especially in 31 spline, is way better supported in the aftermarket world.
Next, Rangers from 98-00 used a special type of locking hubs, which had a front axle that was also a bit different than the ones that followed despite being the same overall axle.
01-02 trucks used a very similar axle that 98-00 trucks used but it was setup to be a live axle.
03 was a bastard year for 4x4, sometime in the year (the date is argued about) the front rotors went from being 11ish inches to 12ish. The only change here was the hubs out, they had new mounts for new calipers (both of which are what need to be replaced to upgrade 01/02/03 trucks to the larger diameter rotors).
04 trucks on remained the same front axle setup until 2011.
In short, to replace your front axle, all you need is a replacement axle from a 01 or newer truck.
Something that just occurred to me... If you have a 4x4 truck, you have a 8.8 rear end... Not sure why I thought you had a 7.5 but oh well.
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Past:
Baby Girl: 2006 XL 3.0 ~RIP~ 1/26/2015
Current:
Penguin: 2002 XLT 3.SLOW 4x2
River/Kaitlyn: 2003 EDGE 3.GO! 4x2... For now?
~Aspiring Mini Level 2~
The Duck: 2003 Ford Ranger FX4 Level 2 - TWIN STICKS!