Going to do oil pickup tube o-ring, what else can I do along the way?

[02FailBlazer]

I've decided that at some point in the future, I'm going to attempt the massive PIA job of dropping the oil pan to replace my oil pickup tube o-ring. Given that this requires taking apart the entire front differential/axle assembly, is there anything else I should do while I've got all that apart?

One thing I've determined is that my 4WD disconnect probably needs some TLC. I discovered there was a clear/pale grease flung all over the place on the passenger side when I was doing suspension work a few months ago and couldn't figure out where it came from until I read a few threads here and figured out it's probably coming from the disconnect. It doesn't look like CV axle grease and it's definitely too thick to be front diff fluid.

Any bearings, seals, etc. I should replace? Other parts?

 

[Mooseman]

Yeah, the seals on the diff is worth it. If the disco is in good shape, just a clean and re-grease will do it. Check the power steering lines since you have to lower the rack anyway.

Any reason why you think you need to do the pickup seal? Did you check the actual oil pressure?

 

[02FailBlazer]

Yeah, the seals on the diff is worth it. If the disco is in good shape, just a clean and re-grease will do it. Check the power steering lines since you have to lower the rack anyway.

Any reason why you think you need to do the pickup seal? Did you check the actual oil pressure?

It's a 24 year old vehicle with 198K miles on it that I wasn't particularly nice to in the past. At this point, I see it as preventative maintenance. This is more of an aspirational, far flung future project, not something I plan to tackle soon but I'd like to assemble a parts list in the mean time.

Assuming the disconnect is generally ok, is it worth installing the Dorman "improved" shift fork or should I just leave it alone?

 

[Mooseman]

Assuming the disconnect is generally ok, is it worth installing the Dorman "improved" shift fork or should I just leave it alone?

It might be worth it if you use 4x4 often. Most go through life without having a failure. I've never had a fork break on me. My '02 I did take apart and refresh the grease. I still haven't looked at my '07's disco yet at 210k km. I will likely do the refresh next time I have that axle out, if ever.