Fulltext TSBs

Technical Service Bulletins

TSB
05-23-3
  • REAR AXLE NOISE REPAIR
Publication Date: November 4, 2005

FORD:
1997-2005 Expedition, F-150
2002-2005 Explorer
LINCOLN:
1998-2005 Navigator
2003-2005 Aviator
MERCURY:
2002-2005 Mountaineer

This article supersedes TSB 05-12-6 to update the Service Kit and Service Procedure information.

ISSUE:

Some vehicles may exhibit an axle whine or hum during acceleration, deceleration and/or cruise.

ACTION:

An axle repair kit has been developed which incorporates most parts required for a comprehensive axle repair. The kit should be used instead of installing a complete axle assembly to repair an axle whine/hum. Replace Ring and Pinion with Axle Kit and Components.

NOTE:REFER TO THE “DIFFERENTIAL RING AND PINION” IN-VEHICLE REPAIR PROCEDURE IN THE ONLINE WORKSHOP MANUAL SECTION 205-00, FOR THE LATEST AXLE DIAGNOSIS AND REPAIR PROCEDURES.

NOTE:FOR 1999 AND PRIOR MODEL YEAR VEHICLES, USE THE 2000 MODEL YEAR WORKSHOP MANUAL.

NOTE:WHEN SERVICING THE REAR AXLE ON ANY 2002-2004 F-150, EXPEDITION, NAVIGATOR, EXPLORER OR MOUNTAINEER BUILT BEFORE 3/30/2004, IF FLUID REPLACEMENT IS REQUIRED, REPLACE THE ORIGINAL FUEL EFFICIENT HIGH PERFORMANCE (FEHP) SAE 75W-90 REAR AXLE LUBRICANT WITH SAE 75W-140 HIGH PERFORMANCE SYNTHETIC REAR AXLE LUBRICANT. WHEN THE FLUID TYPE IS CHANGED, REPLACE THE CURRENT “FEHP” METAL TAG WITH A NEW “75W-140″ TAG (F3TZ-4121-AA). IN ADDITION, REMOVE OR BLOCK-OUT THE FEHP REFERENCE ON THE MULTI-COLORED LABEL LOCATED ON THE RIGHT SIDE AXLE TUBE. IF THE AXLE IS A LIMITED-SLIP MODEL, USE XL3 ADDITIVE FRICTION MODIFIER IN THE QUANTITY RECOMMENDED BY THE WORKSHOP MANUAL.

KIT ORDERING: REFER TO THE VEHICLE AXLE TAG FOR AXLE RATIO IDENTIFICATION

  • 5L3Z-4209-A = (8.8-Inch Ring Gear/3.31 ratio) (1997-2005 F-150)
  • 5L3Z-4209-B = (8.8-Inch Ring Gear/3.55 ratio) (1997-2005 F-150, 2002-2005 Explorer/Mountaineer/Aviator)
  • 5L3Z-4209-C = (8.8-Inch Ring Gear/3.73 ratio) (1997-2005 F-150, 2002-2005 Explorer/Mountaineer/Aviator, 2003-2004 Expedition/Navigator)
  • 5L3Z-4209-D = (9.75-Inch Ring Gear/3.31 ratio) (1997-2005 F-150, 2005 Expedition/Navigator, 1997-2002 Expedition/Navigator)
  • 5L3Z-4209-E = (9.75-Inch Ring Gear/3.55 ratio) (1997-2005 F-150, 1997-2002 Expedition/Navigator)
  • 5L3Z-4209-F = (9.75-Inch Ring Gear/3.73 ratio) (1997-2005 F-150, 1997-2005 Expedition/Navigator)

NOTE:9.75 REAR AXLE HOUSINGS WERE REDESIGNED IN MID-1999, INCREASING FRONT PINION BEARING SIZE. REPLACING RING & PINIONS IN AN OLD-STYLE AXLE ASSEMBLY WILL REQUIRE INSTALLATION OF SPACER P/N YL3Z-4662-CA. SPACER IS TO BE INSTALLED BETWEEN INNER PINION BEARING AND COLLAPSIBLE SPACER.

THE AXLE SERVICE KITS INCLUDE THE FOLLOWING COMPONENTS:

  • 4630 – Head Bearing
  • 4628 – Head Bearing Cup
  • 4676 – Pinion Seal
  • 386989-S2 – Washer (Slinger)
  • 4621 – Tail Bearing
  • 4616 – Tail Bearing Cup
  • 4222 – Differential Bearing Cups
  • 4221 – Differential Bearings
  • 4209 – Gear Set (includes pinion shims, pinion nut and crush spacer)
  • 4209 – Instruction Sheet

NOTE:THE KIT DOES NOT INCLUDE THE FOLLOWING ITEMS. SOME OR ALL OF THESE ITEMS WILL BE REQUIRED TO COMPLETE THE AXLE SERVICE, DEPENDING ON AXLE APPLICATION/STYLE.

ORDER AS NEEDED:

NOTE:REUSE OF RING GEAR BOLTS, CARRIER BEARING CAP BOLTS AND DIFFERENTIAL SLAVE PIN RETAINING BOLT REQUIRES CLEANING OF THREADS AND INSTALLATION OF TA-27 STUD AND BEARING MOUNT RETAINING COMPOUND & SEALANT.

  • YL3Z-4662-CA – Pinion Bearing Spacer for 1997-1998 9.75 axles
  • XG-14 – Gear Marking Compound
  • 4067 – Differential Shims 0.241″ to 0.307″
  • SAE XY-75W140-QL – High Performance Synthetic Rear Axle Lubricant
  • XL-3 – Additive Friction Modifier (Limited Slip Axles Only)
  • 205-506 – Seal Protectors (Rotunda Tool)
  • W710084-S439 – Wheel End Nuts
  • 390266-S100 – Differential Slave Pin Bolt (9.75″ axles)
  • 387426-S100 – Differential Slave Pin Bolt (8.8″ axles)
  • 4B422 – Axle Circlips
  • ZC-21 – Metal Surface Cleaner
  • TA-29 – Ultra Silicone Sealant
  • TA-27 – Stud and Bearing Mount Retaining Compound and Sealer
  • F3TZ-4121-AA – Fluid Tag (REQUIRED IF FLUID TYPE IS CHANGED FROM FEHP DURING REPAIR)

WARRANTY STATUS:

Eligible Under Provisions Of New Vehicle Limited Warranty Coverage

OPERATIONDESCRIPTIONTIME
052303A1997-2002 Expedition, 1998-2002 Navigator, 1997-2004 F-150 Heritage, 2004-2005 F-150: Rear Axle Noise Repair (Includes Time For Road Test To Verify Concern (Beam Axle)) (Do Not Use With 4205A Or 4205A4)4.7 Hrs.
052303A2003-2005 Expedition: Rear Axle Noise Repair (Includes Time For Road Test To Verify Concern (Irs Axle)) (Do Not Use With 4010D Or 4010D4)5.8 Hrs.
052303A2003-2005 Expedition/Navigator With Air Suspension: Rear Axle Noise Repair (Includes Time For Road Test To Verify Concern (Irs Axle)) (Do Not Use With 4010D Or 4010D4)5.9 Hrs.
052303A2002-2005 Explorer/Mountaineer, 2003-2005 Aviator: Rear Axle Noise Repair (Includes Time For Road Test To Verify Concern (Irs Axle)) (Do Not Use With 4010D Or 4010D4)6.6 Hrs.

DEALER CODING

BASIC PART NO.CONDITION CODE
420914