The Ft. Passenger axle slid out of the diff today offroading. Last time I worked on the suspension it slid out some but I lined it back up and slid back together prior to bolting the spindle to the strut.

Earlier today I was on some trails in 15" of snow and I lost 4wd. I got out and looked after not getting it to lock again and seen it slid out again. I'm guessing the retaining clip took a crap and I couldnt get it back together.

I pulled the spindle and got the halfshaft outta the hub and pulled the axle to find the end 1/8" of splines were chewed/mushroomed some and the retaining clip that should lock the assembly into the diff is a small diameter and very easy to compress (aka, not enough tension to lock in like it should).

I'm HOPING I can just file the end of the splines back open and get a new ring providing the diff splines aren't chewed up, but if they are, what are my options as far as replacement?

I have 30x9.5 tires and may put 31x10.5 on next set (not till late next year) so it wouldnt hurt to have a different gearset. I have a 96 3spd auto (tq converter locks at ~47mph) so it's not exactlly peppy anymore after the tires.

Easiest swap would be to pick up a new CV and front diff and just swap them both out.  You should be able to use any 96-98 as they pretty much all have the 5.12 gears with the larger front spline.

Easiest swap would be to pick up a new CV and front diff and just swap them both out.  You should be able to use any 96-98 as they pretty much all have the 5.12 gears with the larger front spline.

Does my Tracker have anything different then 5.12 as it's an automatic instead of manual? I'm still learning a lot about these rigs.

I know at 4k rpm I'm going around 70-75mph on the highway.

If yours is a Stock  2 door, AUTO, it's probably got the 4.30 gearsets in it. If you go to 31" tires, you'd be better off swapping out BOTH sets to the 4.62's or better yet the 5.13's out of a manual. Then replace the cv, and do something about your droop. Have you lowered your diff? How much lift do you have? I installed some limiting straps on my front end. I've got almost 4" of susp lift, lowered diff, Calmini springs with 1.5" spacers, OME struts and strut spacers, lots of additional travel. The limiting straps were necessary to keep the cv's from pulling out.

If yours is a Stock  2 door, AUTO, it's probably got the 4.30 gearsets in it. If you go to 31" tires, you'd be better off swapping out BOTH sets to the 4.62's or better yet the 5.13's out of a manual. Then replace the cv, and do something about your droop. Have you lowered your diff? How much lift do you have? I installed some limiting straps on my front end. I've got almost 4" of susp lift, lowered diff, Calmini springs with 1.5" spacers, OME struts and strut spacers, lots of additional travel. The limiting straps were necessary to keep the cv's from pulling out.

It's 2 door auto.

I cut the arms about 3/4" behind the ball joint spots and extended it 1/2" and shifted them forward 5/8". There is another member that extended his 1/2" and shifted forward 1.5" but his wheels look too far forward so I only did the 5/8". I have not modified any location of the diff tho.

I have 2" spring spacers in the rear with Gabriel crown vic shocks and 1.5" spring spacers in the front with the strut spacers as well, the strut mounts are still "upright".

I also pressed out the stock bushings and put in ES bushings with sleeves and enlarged the front bolt holes and d-bushing bracket for swaybar to 9/16" and have new grade8 bolts for front and rear mounts on the control arms.

Drop the front diff by extenting the brackets, or making new ones. Sounds like you got the skills, so that should keep the cv's intact. Swap out your gearsets for the ones from a manual trans and you'll be good to go.