I like many others purchase a 2023 Ford Explorer ST only to go on the forums and find out this differential is a possible huge problem.
Sooo I bought the Diffy Stiffy after watching a youtube video on the installation, how hard could it be?
WRONG.
The s*** they do not show you is that, in order to access the nut in the subframe after drilling the hole you need WRENCH fingers. NOBODY has WRENCH fingers or a wrench small enough to fit in two TINY holes.
So after trying to install it, drilling holes in the frame, removing the differential bolts, and being unsuccessful for two hours because I do not have wrench finger tips and each time I tried to hold the nut and screw the bolt, it was impossible.
I contacted Fenfab and they were like you just need a stubby wrench to fit in there and it was complete BULL. They shouldn't even sell the product with the nut. So I was pissed I just paid close to $200 for this brace that I cannot install.
Sooo I did some googling and solved it.
First I explored JACK Nuts, which basically think of it like a manual rivet, but it required a very large hole to be drilled
Second solution I explored was a Nut Rivet Tool, M8 specifically since the Fenfab comes with M8 bolts. I tried utilizing the smallest drill bit to make the hole bigger to insert the rivet, but ended up using the 1/2 drill but which worked perfectly.
https://a.co/d/dzroY75
*This link is now updated for steel rivets
I followed the instructions and now the brace is torqued on there, my rivets are installed and I am happy.
If you are doing this for the first time, I recommend drilling the initial holes first with the brace with the small recommended drill bit, then taking the brace off, and widening the hole with 1/2.
I also learned the hard way, when utilizing the rivet tool, compress the handle so that you can easily screw out from the rivet. I utilized pliers on the knob and it took forever for the first rivet.
Your welcome, you can now buy the Diffy Stiffy courtesy of my hard work. Just allocate another $22 for that rivet tool.
*Additional update, despite the comments on aluminum rivets, looked up the strength for each 5/16 or m8 rivet the upset load and ultimate load minimum is 1900 lbs and 4000lbs respectively for each rivet. So together the weight capacity is doubled and they can hold 2/3 +weight of the vehicle. The explorer st is 5500 lbs (got it weighed for commercial plates for my side business). So you’re safe with either option aluminum or steel. Steel strength is 2x what’s listed and your rear differential weighs 66lbs if you were to buy it brand new.
So fenfab is actually wayyy more than enough to hold a diff, and even more expensive options are even more overkill.
Sooo I bought the Diffy Stiffy after watching a youtube video on the installation, how hard could it be?
WRONG.
The s*** they do not show you is that, in order to access the nut in the subframe after drilling the hole you need WRENCH fingers. NOBODY has WRENCH fingers or a wrench small enough to fit in two TINY holes.
So after trying to install it, drilling holes in the frame, removing the differential bolts, and being unsuccessful for two hours because I do not have wrench finger tips and each time I tried to hold the nut and screw the bolt, it was impossible.
I contacted Fenfab and they were like you just need a stubby wrench to fit in there and it was complete BULL. They shouldn't even sell the product with the nut. So I was pissed I just paid close to $200 for this brace that I cannot install.
Sooo I did some googling and solved it.
First I explored JACK Nuts, which basically think of it like a manual rivet, but it required a very large hole to be drilled
Second solution I explored was a Nut Rivet Tool, M8 specifically since the Fenfab comes with M8 bolts. I tried utilizing the smallest drill bit to make the hole bigger to insert the rivet, but ended up using the 1/2 drill but which worked perfectly.
https://a.co/d/dzroY75
*This link is now updated for steel rivets
I followed the instructions and now the brace is torqued on there, my rivets are installed and I am happy.
If you are doing this for the first time, I recommend drilling the initial holes first with the brace with the small recommended drill bit, then taking the brace off, and widening the hole with 1/2.
I also learned the hard way, when utilizing the rivet tool, compress the handle so that you can easily screw out from the rivet. I utilized pliers on the knob and it took forever for the first rivet.
Your welcome, you can now buy the Diffy Stiffy courtesy of my hard work. Just allocate another $22 for that rivet tool.
*Additional update, despite the comments on aluminum rivets, looked up the strength for each 5/16 or m8 rivet the upset load and ultimate load minimum is 1900 lbs and 4000lbs respectively for each rivet. So together the weight capacity is doubled and they can hold 2/3 +weight of the vehicle. The explorer st is 5500 lbs (got it weighed for commercial plates for my side business). So you’re safe with either option aluminum or steel. Steel strength is 2x what’s listed and your rear differential weighs 66lbs if you were to buy it brand new.
So fenfab is actually wayyy more than enough to hold a diff, and even more expensive options are even more overkill.
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