2003 Rear axle whine

Spell check and are not friends. I have no clue what Calcification on rear axle noise is. It should read something like clarification.

/Richard

Hey! You just described my 2004. It went out of warrenty last month. Should I be worried?

dickm

Nope, you've got the whine

When you take your foot off the gas you take the load off the bearings

Better hurry !!!!!!!!!!!

Yes

TSB 05-23-3 11/28/05

REAR AXLE NOISE REPAIR\

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 YL3Z4662-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)

- W710084-5439 - Wheel End Nuts

- 390266-S199 - 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 OPERATION DESCRIPTION TIME

052303A 1997-2002 Expedition, 4.7 Hrs. 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)

052303A 2003-2005 Expedition: 5.8 Hrs. Rear Axle Noise Repair (Includes Time For Road Test To Verify Concern (lrs Axle)) (Do Not Use With 4010D Or 4010D4)

052303A 2003-2005 5.9 Hrs. Expedition/Navigator With Air Suspension: Rear Axle Noise Repair (Includes Time For Road Test To Verify Concern (lrs Axle)) (Do Not Use With 4010D Or 4010D4)

052303A 2002-2005 6.6 Hrs. Explorer/Mountaineer, 2003-2005 Aviator: Rear Axle Noise Repair (Includes Time For Road Test To Verify Concern (lrs Axle)) (Do Not Use With 4010D Or 4010D4)

DEALER CODINGCONDITION BASIC PART NO.CODE 420914

OASIS CODES: 509000, 590000, 597997, 702000, 702200, 703200, 703300,

703400, 790000

I called the local Ford store and they said it sounds like the bearings to them. They will test drive to confirm the problem then order the parts. I will let everyone know how it all comes out!

/Richard

The local FORD store (where I bought the last 3 vehicles from) asked me to come in Saturday morning at 7:30 so the service guy could verify the problem. They feed me a sausage biscuit and had me on my way by 8:00. They are ordering the bearing kit or whatever to install as soon as it comes in. Looks good so far.......

/Richard

This is an inherent design problem with many Fords. I have a 2002 F-150 with the same thing. Took it to the dealer, under warranty, who inspected it and said everything was OK. But it still whines 40K later. My wife's 2004 Sport Trac has the same problem. This is one reason why Ford is loosing market share to Toyota and everyone else. They won't do what they need to do to put these kind of problems to bed. I don't believe it has anything to do with the bearings. I believe it has to do with an improper meshing of the ring and pinion gears. My truck now has

57K on it and the noise is the same. Ron

Going in Tuesday to get the repair done. They said to plan on leaving it all day.

/Richard

Well it really went in today to the shop. 07/05/06 warranty expires

07/31/06. They did not have a loaner car for my wife so the service manager took her home. Which was pretty nice of them. Is there any particular "test" that can be done to make sure everything is OK, or at least not worse?

Thanks Richard

Last post on this subject (I hope)

1. Truck went in shop 7/5/06. Service guy carried my wife home. (we live about 15 miles from shop)
2. Shop delivered truck back at house 07/07/06.
3. Fixed the following items: Put in rear end bearing kit Replaced rear driver side power window motor. (again) Replaced black door pillar panels on both sides that had become discolored. Put a few bucks of gas in truck
4. Charge: 1. Truck went in shop 7/5/06. Service guy carried my wife home. (we live about 15 miles from shop) 2. Shop delivered truck back at house 07/07/06. 3. Fixed the following items: Put in rear end bearing kit Replaced rear driver side power window motor. (again) Replaced black door pillar panels on both sides that had become discolored. Put a few bucks of gas in truck 4. Charge: $0 5. I tested the truck Sunday and the rear whine is not noticeable.
5. I tested the truck Sunday and the rear whine is not noticeable.

All in all, not a bad experience at all. I suggest Freedom Ford in Centre, Al if you live anywhere around here. They also listen to my other complaints and offer suggestions on how to fix them myself on my '99 Explorer and '01 SuperCrew. So far so good, I have my fingers crossed!

Thanks everyone! Richard Grimes

I took my '04 Explorer in yesterday to have my whine fixed. It was one month out of warrenty. For a $300 "owner participation fee" they agreed to fix it. Got the car back and it's never been so silent. In fact, now I hear all the other noises it makes that I didn't hear before :-)

I hope it stays this way. The dealer claims they redesigned the gears.

Overall, they did a good job. Dropped it off in the morning, it was done that evening.

dickm

The TSB was posted at the beginning of this thread. you can google for it if you missed it. Here's the TSB header

TSB 05-23-3 11/28/05

REAR AXLE NOISE REPAIR\

FORD:

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

So yes, it does cover 2005.

I'd print out the TSB and take it with you to the dealer. But they wouldnt fix mine until they verified for themselves that it had whine. They wouldnt take my word for it. BTW, 57 mph was the magic speed on mine where it sounded the worst.

dickm